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RELATED APPLICATIONS
[0001] This application is a continuation of U.S. application Ser. No. 09/478,389, filed Jan. 6, 2000, which claims the benefit of U.S. Provisional Application No. 60/115,011, filed on Jan. 7, 1999, U.S. Provisional Application No. 60/134,896, filed May 19, 1999 and U.S. Provisional Application No. 60/157,872, filed Oct. 6, 1999, and U.S. patent application entitled “Hearing Aid with Large Diaphragm Microphone Element Including a Printed Circuit Board”, Attorney Docket No. 2506.1008-001, filed Jan. 6, 2000, the contents of each of which are incorporated herein by reference.
BACKGROUND OF THE INVENTION
[0002] The performance of a hearing aid depends, among other things, upon the design of the microphone assembly which includes the microphone transducer, sound port, and a housing containing the signal processing electronics. The microphone transducer is typically a variable capacitor or electret type microphone formed of a charged diaphragm forming one plate of the capacitor and a backplate forming the other terminal. Sound impinging on the diaphragm varies the capacitance and produces a voltage signal proportional to the sound waves which is picked off the backplate and coupled to signal processing circuits where it is amplified in an amplifier and electrically processed to, inter alia, reduce noise content. The processed signal is then coupled to a receiver and converted back to sound waves to aid the user.
[0003] Conventional in the ear (ITE) or in the canal (ITC), hearing aids must of necessity be of relatively small size. Therefore, such aids have been fabricated with accessible replaceable batteries which are accessed via a faceplate door on the hearing aid enclosure. These size and battery requirements cause the microphone assembly and also the diaphragm to be relatively small in size in relation to the size of the hearing aid faceplate. The small diaphragm size lowers the quality of the transducer function.
[0004] An electret microphone for hearing aids typically uses a Junction Field Effect Transistor (JFET) buffer to convert the voltage signal from the high impedance transducer source to a low impedance source. This impedance conversion typically requires a difficult connection to be made to a high quality and hence, expensive substrate on a Printed Circuit Board (PCB) containing the signal processing components, so as to avoid compromising the input impedance of an amplifier on the substrate.
SUMMARY OF THE INVENTION
[0005] This invention is directed to a microphone assembly for a hearing aid comprising a metal housing with a front wall with sound openings and a side wall extending longitudinally away from the front wall. Within the housing is an electret type microphone or transducer having a diaphragm electrode and a backplate electrode. External sound entering through the openings are converted into an electrical voltage signal which is coupled from the backplate to a Junction Field Effect Transistor (JFET) buffer device. The buffered signal is then coupled to an amplifier and signal processing components within the housing.
[0006] In one embodiment of the invention, the JFET device is a flip-chip component with four active terminals. Drain, source, bias and gate terminals are provided. The gate terminal is located on a side of the flip-chip proximal to and adjacent the backplate. The other terminals are connected to respective traces on a PCB. All the signal processing circuits needed to provide a functional hearing aid are contained on the PCB. The PCB also provides an acoustic seal to a back volume of the microphone and contains an electromagnetic interference (EMI) ground shield in the form of a ground plane of conductive material extending across the side wall of the housing.
BRIEF DESCRIPTION OF THE DRAWINGS
[0007] The foregoing and other objects, features and advantages of the invention will be apparent from the following more particular description of preferred embodiments of the invention, as illustrated in the accompanying drawings in which like reference characters refer to the same or similar parts throughout the different views. The drawings are not necessarily to scale, emphasis instead being placed upon illustrating the principles of the invention.
[0008] A more detailed understanding of the invention may be had from the following description of preferred embodiments, given by way of example and to be understood in conjunction with the accompanying drawing, wherein:
[0009] [0009]FIG. 1 is a schematic side view of a first embodiment of the invention in which a microphone assembly contains a JFET buffer with source/drain flip-chip pads and a backside gate fastened to a microphone backplate.
[0010] [0010]FIG. 2 is an exploded view of the assembly of FIG. 1.
[0011] [0011]FIG. 3, is an enlarged schematic detail of the JFET buffer portion of FIG. 2 prior to assembly.
[0012] [0012]FIG. 4 is a detail as in FIG. 3 after assembly.
DETAILED DESCRIPTION OF THE EMBODIMENTS
[0013] In the apparatus and method of the invention, an electret microphone for hearing aids uses a JFET buffer to convert the signal from the backplate, i.e., a high impedance source (the microphone) to a low impedance source. This impedance conversion results in a higher level loaded output signal level to the hearing aid amplifier than would be produced from the condenser microphone element itself without a buffer. A JFET gate contact to the backplate of the microphone's condenser must somehow be made. A direct connection from a small pad on the JFET to the microphone backplate is difficult to do and the use of an intermediate wire bond pad requires that the pad be mounted on ceramic, which complicates assembly. If the JFET gate connection is on the PCB substrate, the substrate must have high resistivity to not compromise the input impedance of the amplifier. A ceramic (alumina) substrate has such properties. The electrical connections for the JFET can be wire bonded from the microphone element onto a ceramic substrate. However, wire bonds are normally formed with a loop from pads on the JFET to extra bonding pads on the ceramic substrate, a practice that requires extra space vertically and horizontally and produces stray capacitance to ground and other circuit nodes which reduce sensitivity and introduce noise. Other disadvantages of a ceramic substrate itself are that it is relatively costly for use in a disposable hearing aid application. It also has a high dielectric constant which makes stray capacitance even higher.
[0014] In accordance with the embodiment shown in FIGS. 1 - 4 , flip chip technology is used to minimize the physical size and lead lengths required to connect die bond pads of a JFET 10 to reduce the lead length between the electret microphone backplate 12 and the JFET. The result is a lower noise and higher sensitivity connection than could be made by longer paths formed by conventional wiring. The JFET backside gate 14 is connected to the backplate 12 by conductive epoxy 20 . This keeps the connection to the JFET off the PCB substrate 18 so that a lower cost substrate such as a glass-epoxy printed circuit board (e.g., FR4) maybe used. Since the JFET gate 14 does not contact the substrate 18 and then connect to the microphone backplate 12 (rather the JFET is connected to the backplate directly), the stray capacitance should be lower and, hence, sensitivity should be higher.
[0015] [0015]FIG. 1 is a sectional view of this embodiment of the hearing aid microphone module or assembly 100 and FIG. 2 is an exploded view of the assembly 100 . Assembly 100 contains all the electronic components other than the battery and a receiver necessary for a functional hearing aid. A circular metallic cover 40 is provided with a large diameter opening 52 for passage of sound from a faceplate (not shown) of a hearing aid enclosure in which the assembly 100 is adapted to be disposed proximally adjacent thereto. Sound impinges on large circular diaphragm 54 supported and attached to circular frame 42 and underlying spacer 44 which prevents the diaphragm 54 from contacting backplate 12 . Backplate 12 , in turn, is supported at its edges by an insulative bushing, such as, PTF and is disposed over PCB 16 and acoustically and electrically sealed to cover 40 by a conductive cement, such as, epoxy. This partial assembly is then attached by snap ring 48 to electrical component PCB 50 .
[0016] [0016]FIGS. 3 and 4 show details of the flip-chip JFET connections including the gate to backplate connection 14 using conductive epoxy 20 . FIG. 3 is an exploded view before assembly, while FIG. 4 shows the JFET after assembly with the PCB 16 and the backplate 12 . The metallization 22 on the top of the JFET die 10 is the gate connection, which is a very high impedance point. The solder bumps 24 on the bottom are the low impedance connections such as the drain and source connections. In this embodiment of the invention, four solder bumps: Drain, Source, Bias, and one dummy solder bump that is a No-Connect (NC) are provided. (NC is not connected to any part of the JFET circuit.) The underfill material 28 provides mechanical support.
[0017] This embodiment of the invention produces the following advantages:
[0018] a. A flip-chip JFET 10 with no gate contact made to the PCB, allows use of low cost FR4 or other such materials instead of ceramic for the PCB substrate.
[0019] b. By controlling the depth of the front chamber 30 in the microphone assembly so that the spacing from the backplate to the PCB substrate is small enough, a single blob of conductive (epoxy) cement 20 is sufficient to bridge the gap, eliminating the need for wire bonds.
[0020] c. Stray capacitance from the gate to PCB substrate is reduced because of this gate isolation, resulting in decreased signal loss and decreased noise pickup.
[0021] d. The use of four dummy solder balls on JFET provides better mechanical support and alignment during assembly. (Solder bumps on Drain, Source, Bias, and NC solder bumps 752).
[0022] Equivalents
[0023] While this invention has been particularly shown and described with reference to preferred embodiments thereof, it will be understood by those skilled in the art that various changes in form, modification, variation and details may be made therein without departing from the scope of the invention as defined by the appended claims. | A hearing aid microphone module housing all the electronic components needed for a functional hearing aid other than the battery and receiver is described which uses flip-chip technology to couple a JFET buffer to the components. The buffer is disposed on a PCB which defines a back volume of the housing. | 7 |
FIELD OF INVENTION
The present invention relates to a silkscreen printer machine comprising a support structure and at least one printing station secured to the structure and including at least one screen support presenting a reception area adapted to receive a screen texture having a pattern for printing placed thereon.
BACKGROUND OF THE INVENTION
As is known per se, articles are printed in a silkscreen printer machine in a printing station by pressing a wiper blade against a silkscreen texture, the texture being squeezed between the article and the blade.
While printing flat articles, such as compact disks, telephone cards, or solar cells, the articles for printing are placed on a turntable suitable for transferring them between various processing and printing stations.
In conventional manner, the printing station comprises a support structure, a screen support secured to the structure, and a blade-carrier carriage mounted on a support beam secured to the support structure and extending along a side face of the screen support.
The blade-carrier carriage is guided in translation on the support beam so as to enable the screen to be wiped by the blades. During the displacement of the blade-carrier carriage, the pattern for printing is pressed against the article by the blade pressing against the mesh of the screen and by said mesh coming into contact with the surface of the article for printing.
Such a printer machine is described in particular in patent document FR 2 666 050. In that document, the side face of the screen support is secured at two points to the support beam. The screen support is cantilevered out from the support structure over the turntable and thus over the article for printing.
Nevertheless, it has been found that the printing of the pattern on the article is not uniform. Such a printer machine therefore cannot be used for printing that requires printing of great precision, as is the case for printing solar cells where precision of one hundredth of a millimeter is required.
SUMMARY OF THE INVENTION
An object of the invention is to provide a printer machine of great precision.
To this end, the invention provides a printer machine of the above-specified type, characterized in that the screen support is carried by at least three support elements secured to the structure, said support elements not being in alignment and being positioned on either side of the reception area.
In particular embodiments, the printer machine includes one or more of the following characteristics:
transport means for transporting at least one article for printing to bring it into register with the reception area, the transport means comprising at least one holding place for holding the article for printing; lift means for the support element secured to the support structure and suitable for causing the screen support to move towards and away from the holding place; the lift means comprise lift means common to all of the support elements; at least fifty percent of the reception area is inscribed in a polygon whose summits are positioned at the points of contact between the support elements and the screen support; the reception area is fully inscribed within said polygon; the transport means comprise a circular turntable provided with a central orifice, and one of the support elements passes through said central orifice; two support elements are positioned on a tangent to the turntable; and the machine includes at least one locating station comprising means for determining the thickness of the article for printing, and control means for controlling the lift means of the support elements as a function of the thickness determined for the article.
The invention also provides printer apparatus, characterized in that it comprises:
a printer machine as mentioned above; at least one feed conveyor for feeding articles for printing, the conveyor having an unloading place for unloading articles for printing, and a storage place for storing articles for printing; and at least one first transfer device for transferring articles for printing, the transfer device comprising an arm hinged about a pivot axis positioned at equal distances from the unloading place and from the storage place.
In particular embodiments:
the feed conveyor is positioned relative to the printer machine in such a manner that the hinged arm of the first transfer device is adapted firstly to turn through an angle of 120° between the loading place and the holding place, while also simultaneously causing the article to turn in a horizontal plane through an angle of 120°; and the apparatus comprises:
at least one removal conveyor for removing correctly-printed articles, said conveyor having a first loading place for receiving printed articles; at least one removal conveyor for removing defective articles, said conveyor including a second loading place for receiving printed articles; and at least one second transfer device for transferring printed articles, being positioned at equal distances from the first and second loading places and from the holding place; and
the printer machine includes a checking station for checking articles after printing, and control means adapted to control the second transfer device so as to transfer the printed articles from the holding place to the first loading place or to the second loading place as a function of the state of each checked article.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention can be better understood on reading the following description given purely by way of example and made with reference to the drawings, in which:
FIG. 1 is a perspective view of a first embodiment of printer apparatus of the invention; and
FIG. 2 is a plan view of the printer apparatus shown in FIG. 1 .
DETAILED DESCRIPTION OF THE INVENTION
The printer apparatus 2 of the invention is shown diagrammatically in FIGS. 1 and 2 . It comprises a feed conveyor 4 for feeding articles 6 for printing, a printer machine 8 , a removal-conveyor 10 for removing properly printed articles, and a removal conveyor 12 for removing articles that are badly printed or defective, and extending perpendicularly to the conveyor 10 .
The feed and removal conveyors 4 , 10 , 12 are identical, each comprising a support structure 14 and a looped conveyor belt 16 held between two parallel deflection rollers, one of which is driven by a brushless motor 18 .
Articles 6 for printing, such as solar cells, for example, are placed on the conveyor belt 16 one after another on support zones 20 . The support zone 20 situated at the end of the feed conveyor 4 close to the printer machine 8 defines an unloading place 22 for unloading articles for printing. The support zones 20 situated at the ends of the removal conveyors 10 and 12 close to the printer machine 8 define first and second loading places 24 and 26 for loading printed articles.
A storage device 28 for storing articles 6 for printing is associated with the feed conveyor 4 . It comprises a rectangular storage tray 30 and a support bracket 32 in the form of a square having one end secured to a side face of the tray 30 and its other end secured to the support structure 14 .
The storage tray 30 is of a size that is slightly greater than the size of the articles 6 for printing and it presents a storage zone 34 on which said articles can be stacked while the printer machine 8 is not in operation, for example while the screen texture is being washed.
A monitor camera 35 for monitoring the existence of articles 6 for printing on the storage place 34 and on the conveyor belt 16 is located facing the conveyor 4 . The operation of this camera is described below.
A feed transfer device 36 is interposed between the feed conveyor 4 and the printer machine 8 . It is suitable for moving articles 6 between the unloading place 22 and an article-holding place 38 that is situated on the printer machine 8 . It is also suitable for turning the article round on himself through an angle of 120°.
An opposite movement is performed by a removal transfer device 40 interposed between the printer machine 8 and the removal conveyors 10 and 12 , in order to transport printed articles 6 on the removal conveyors 10 , 12 after printing.
The feed and removal transfer devices 36 and 40 are identical. Each comprises a cylindrical stand 42 extending along a vertical axis A-A′, provided with an arm 44 that is articulated about the axis A-A′ and that projects away therefrom and perpendicularly thereto. A gripper element 46 for gripping articles is secured to the free end of the arm 44 . It comprises a body in the form of a rectangular block having a suction device mounted thereon that enables articles to be lifted and held.
The transfer devices 36 and 40 include means (not shown) for driving the stand in an axial direction relative to the axis A-A′ and means (not shown) for driving the arm 44 to turn around the axis A-A′.
As can be seen in FIG. 2 , the stand 42 of the feed transfer device 36 is positioned at equal distances from the unloading place 22 , the storage place 34 , and the holding place 38 , such that when the arm 44 turns around the axis A-A′, the gripper element 46 is adapted to take articles 6 for printing from the unloading place 22 or the storage place 34 , and to lay said articles on the storage place 34 or the holding place 38 .
Similarly, the stand 42 of the removal transfer device 40 is positioned at equal distances from another retaining place 38 of the printer machine and from the loading places 24 and 26 of each of the removal conveyors.
The printer machine 8 comprises a support structure 48 supporting a turntable 50 in the form of a disk, means (not shown) for sequentially driving the turntable about its central axis B-B′ relative to the support structure, and three processing stations 52 , 54 , and 56 disposed at the periphery of the turntable 50 .
The turntable 50 moves the articles 6 from one processing station to another. It carries three holding places 38 for holding articles for printing that are disposed on the top face of the turntable 50 , on which the articles 6 are placed, and under which suction units 60 are mounted to hold the articles 6 in place.
The holding places 38 are rectangular or square in shape and they are situated on the turntable 50 in such a manner that two of their sides are parallel to a tangent to the turntable. They are regularly spaced apart angularly, such that they are at angles of 120° relative to one another.
The processing stations 52 , 54 , and 56 disposed at the periphery of the turntable 50 in register with each holding place 38 comprise, positioned side by side and at equal distances from one another: a locating station 52 for locating the zone for printing on an article 6 ; a printing station 54 ; and a checking station 56 for checking the zone printed on the article 6 .
The locating station 52 comprises a locating camera 62 suitable for viewing the article 6 for printing and a sensor 64 for measuring its thickness, e.g. an infrared sensor or a laser sensor. The camera 62 and the sensor 64 are situated close to the feed conveyor 4 and facing the holding place 38 when the turntable 50 is stationary.
The checking station 56 for checking the article 6 for printing comprises a checking camera 66 suitable for viewing the article 6 after printing. The camera 66 is situated close to the removal conveyors 10 and 12 , and facing a holding place 38 when the turntable 50 is stationary.
The printing station 54 comprises a screen support 68 having an area 69 for receiving a screen texture 70 and a blade and backing blade system 72 suitable for pressing against the mesh of the screen to apply the pattern for printing on the article.
The blade and backing blade system 72 comprises two blades suitable for moving vertically under drive from an actuator 74 , and a carriage 76 carrying the blades and the actuator. The carriage 76 is guided on a support beam (not shown) secured to two opposite sides of the screen support 68 .
The screen support 68 extends over the turntable 50 . It is supported on three pillars 78 that ensure stability. These pillars 78 form support elements for the screen support 68 . They are positioned in non- aligned manner on either side of two opposite sides of the reception area 69 .
The reception area 69 is defined by means for securing the screen texture 70 to the screen support 68 . In order to ensure that the screen texture 70 is stable, the reception area 69 is inscribed within a triangle whose summits are situated at the three points of contact of the pillars 78 to the screen support 68 . This triangle is defined in a horizontal plane.
In particular, two of the pillars 78 of the screen support 68 are positioned on a tangent to the turntable 50 , while the other pillar 78 lies on the axis of the turntable 50 .
In the embodiment of the invention shown in the figures, one of the pillars 78 lies on the axis of rotation B-B′ of the turntable 50 , however it is also possible for this pillar 78 to be positioned away from said axis, along the rim of the screen support 68 .
Thus, two opposite sides of the screen support 68 are held securely, unmoving, and stable so that when the blades press the mesh of the screen texture 70 against the article 6 for printing, the distance between the mesh and the article 6 is constant along the entire length of the mesh over which the blades pass.
The pillars 78 are suitable for being moved vertically in order to adjust the distance between the screen texture 70 and the article 6 for printing as a function of the height of the article 6 as determined by the sensor 64 .
For this purpose, the pillars 78 are mounted to slide lengthwise perpendicularly to the plane of the support screen 68 on an actuator 80 . This actuator constitutes common lift means adapted to raise and lower all three pillars 78 simultaneously.
Thus, it is possible to adjust the distance between the screen texture 70 and the article 6 for printing in a manner that is precise so as to improve the quality of printing and avoid breaking an article that is fragile.
The screen support 68 is mounted to move relative to the pillars 78 in order to position the screen texture 70 exactly in register with the article 6 for printing. In particular, the screen support 68 is mounted to move radially and tangentially relative to the turntable 50 and can turn around the center of gravity defined by the positions in a horizontal plane of the three points where the pillars 78 are secured to the screen support 68 .
The printing station 54 further comprises means that are not shown for moving the screen support 68 in radial and tangential translation and in rotation.
The monitor camera 35 , the locating camera 62 , the checking camera 66 , the two transfer devices 36 and 40 , the drive means for the turntable 50 , the blade and backing blade system 72 , and the means for moving the screen support 68 are connected to a unit 82 for controlling and synchronizing the printer apparatus.
This control unit 82 is adapted to control the printer apparatus 2 as a whole so as to transfer and print articles 6 in series. In particular, it is suitable for controlling the pivot angle of the arm 44 of the feed transfer device 36 as a function of the operating state of the printing station 54 and as a function of the presence of articles 6 for printing on the feed conveyor 4 or on the storage device 38 , where said presence is determined as a function of images delivered by the monitor camera 35 .
The control unit 82 is suitable for calculating the position to be taken by the screen support 68 so that the pattern is applied accurately on the article, on the basis of the image received by the locating camera 62 and as a function of the thickness of the article for printing as measured by the sensor 64 .
For this purpose, the control unit 82 is adapted to compare the image viewed by the locating camera 62 with a prerecorded image where the desired printing zone is defined relative to the shape of the article or relative to previously-printed patterns, and to control the displacement of the screen support 68 as a function of the result of said comparison.
The control unit 82 is also suitable for controlling the angle of rotation of the arm 44 of the removal transfer device 38 as a function of the image viewed by the checking camera 66 is order to position properly-printed articles on the loading place 24 of the conveyor 10 , and poorly-printed articles on the loading place 22 of the conveyor 12 .
For this purpose, the control unit 82 compares the image viewed by the checking camera 66 with the prerecorded image used for determining the displacement of the support screen 68 .
Initially, the feed conveyor 4 transports the articles 6 for printing on the conveyor belt 16 to the unloading place 22 .
If the printing station 54 is in a normal operating state, the control unit 82 causes the feed transfer device 36 to transport the articles 6 for printing situated at the unloading place 22 to the holding place 38 .
For this purpose, the stand 42 of the transfer device 36 moves down and the gripper element 46 picks up the article 6 for printing by suction. Thereafter the stand 42 rises and turns through an angle of 120° about the axis A-A′.
Thereafter, the stand 42 moves down to the height of the turntable 50 . The article 6 for printing is laid on the holding place 38 of the turntable by turning of the suction device.
When the printing station 54 is in a non-functional state, for example while the screen texture 70 is being washed, the stand 42 turns through an angle of 90° and the article 6 for printing is unloaded onto the storage place 34 .
When the monitor camera 35 detects that there are no articles for printing on the feed conveyor 4 , it sends this information to the control unit 82 , which then controls the feed transfer device 36 so that it loads articles 6 for printing from the storage place 34 onto the holding place 38 .
At the locating station 52 , the camera 62 views the article for printing and transmits the viewed image to the control unit 82 which uses this image to determine the exact position of the article for printing, together with its shape, the center of the article, or an earlier printing thereon.
In parallel, the sensor 64 determines the thickness of the article 6 for printing and transmits this information to the control unit 82 .
The turntable 50 begins by turning through an angle of 120° so that the article for printing comes into register with the screen texture 70 of the printing station.
The control unit 82 calculates the position to be taken up by the screen support 62 relative to the holding place 38 to ensure that the pattern printed through the screen texture 70 is correctly positioned on the article 6 for printing.
Thereafter, the control unit 82 causes the actuator 80 to lift the screen support 68 as a function of the thickness of the article 6 for printing as measured at the locating station 52 .
The control unit 82 then causes the radial, tangential, and rotational displacement means of the screen support 68 to position the screen texture 70 in register with the zone for printing on the article as defined by the unit 82 from the image viewed by the camera 62 and from a prerecorded image.
Once the turntable has finished turning through 120°, and the article is in register with the screen texture, the control unit 82 causes the actuator 74 to press the blades against the mesh of the texture 70 and also causes the blade-carrier carriage drive means to operate so that the blades move right across the screen texture 70 .
After the blades have been raised, the control unit 82 causes the turntable 50 to turn through an angle of 120° so that the article 6 for printing is transferred to the checking station 56 .
In this station, the camera 66 views the zones printed on the article and transmits the resulting image to the control unit 82 which compares said image with the predefined image defining the exact position for the pattern that is to be printed on the article.
When the article 6 has been printed correctly, the control unit 82 controls the removal transfer device 38 so that it turns through an angle of 120° in order to position the printed article 6 on the first loading place 24 of the removal conveyor 10 .
When the article has been badly printed, i.e. when the printing it not sufficiently precise or when the article has broken during printing, the control unit 82 causes the removal transfer device to pivot through an angle of 90° so as to bring the printed article onto the second loading place 26 belonging to the removal conveyor 12 for taking away reject printed articles. | A silkscreen printer machine ( 8 ) includes:
a support structure ( 48 ); and at least one printing station ( 54 ) secured to the structure ( 48 ) and including at least one screen support ( 68 ) presenting a reception area adapted to receive a screen texture ( 70 ) having a pattern for printing placed thereon. The screen support ( 68 ) is carried by at least three support elements ( 78 ) secured to the structure ( 48 ), the support elements ( 78 ) not being in alignment and being positioned on either side of the reception area ( 69 ). The invention also provides associated printer apparatus. | 1 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The invention relates to a preparation for shrinkproofing wool.
2. Description of the Prior Art
It is well known that wool, in the untreated state, shrinks and felts on being laundered in an aqueous liquor. In order to counteract this shrinking and felting, chemical treatments have already been recommended in which the structure of the wool is changed or in which finishes are used which contain resin which deposits on the surface of the wool fibers, enveloping these. By both processes, however, products are obtained whose so-called hand is regarded as unpleasant by the consumer.
It has also already been recommended that the shrinkage of wool of laundering be reduced by treatment with organosilicon compounds. Such compounds are described in British Pat. Nos. 594,901, 613,267, and 629,329. In accordance with these processes, the wool is treated with certain silanes.
A process for the prevention of shrinkage of wool is described in British Pat. No. 746,307, in which the wool fibers are finished with particular organopolysiloxanes. Admittedly, a certain degree of shrinkproofness is achieved by this process, however, this effect is not washfast.
German Offenlegungsschrift No. 1,769,249 discloses a process for the treatment of fibrous material, for example, of wool, in which organosiloxanes which contain mercaptopropyl groups are used in the form of an emulsion. With these compounds, however, it is merely possible to achieve a soil repellent effect. The compounds are not suitable for making wool shrink-resistant.
German Offenlegungsschrift No. 2,912,431 discloses an organopolysiloxane latex which consists of the product of the polymerization of a cyclic organopolysiloxane of the general formula ##STR1## in which R 2 and R 3 which may be the same or which may differ from each other, represent substituted or unsubstituted monofunctional hydrocarbon radicals with 1 to 10 carbon atoms and
n has an average value of 3 to 6,
in the presence of
(A) an organofunctional trialkoxysilane of the general formula
(R'O).sub.3 SiRX,
in which
R' represents a monofunctional hydrocarbon radical with less than 7 carbon atoms or a group of the formula
--CH.sub.2 OC.sub.2 H.sub.5 or --CH.sub.2 CH.sub.2 OCH.sub.3,
R represents a bifunctional hydrocarbon group with not more than 12 carbon atoms, and
X represents an organofunctional radical of the formula
--NH.sub.2, --CH.sub.2 CH.sub.2 NH.sub.2 or --(CH.sub.2).sub.4 NH.sub.2
or radicals with the name of N-cyclohexylamino, N-phenylamino, N-aminoethylamino, N,N-dimethylaminoglycidyl, 3,4-epoxycyclohexyl, mercapto or methacrylo,
(B) a surface active material, and
(C) water.
With such preparations, is is admittedly possible to influence the hand and, within certain limits, the wettability and the water repellency of the wool. However, as will also be shown in a comparison example, it is not possible to finish the wool with these latexes so that it will not felt.
German Offenlegungsschrift No. 2,725,714 describes a siloxane-in-water emulsion which contains
(A) a polydiorganosiloxane,
(B) an organosiloxane with at least 3 silicon bonded hydrogen atoms and alkyl radicals with fewer than 19 carbon atoms as organic substituents, and
(C) one or more cationic and/or nonionic emulsifiers.
It is characterized by the fact that the polydiorganosiloxane (A) has a molecular weight of at least 2,500 and terminal OX radicals, X being a hydrogen atom, an alkyl radical with 1 to 15 carbon atoms or an alkoxyalkyl radical with 3 to 15 carbon atoms. At least two of the silicon bonded substituents of the polydiorganosiloxane are monofunctional radicals of carbon, hydrogen, nitrogen, and optionally, oxygen, which contain at least two amino groups and are linked through a silicon-carbon bond to silicon. Also, at least 50% of all substituents of the polydiorganosiloxane are methyl groups and the otherwise present substituents are monofunctional hydrocarbon radicals with 2 to 20 carbon atoms, and the emulsion additionally contains (D) magnesium sulfate and/or sodium sulfate.
This emulsion is intended to be useable for the treatment of goods made of keratinous fibers, for example, for the treatment of sweaters. It is a disadvantage of these emulsions and also of the diluted liquors prepared from them that the splitting off of hydrogen from the silyl hydrogen containing siloxanes is accelerated by the amino groups of the amino alkyl modified siloxane diols. This impairs and shortens the stability of the emulsions and of the diluted liquors. At the same time, the effectiveness of the liquor is reduced, as will also be shown by a comparison example below. Moreover, it turns out that especially bright and naturally colored wool yellows when treated with these products.
Accordingly, it was not possible to shrinkproof wool perfectly and entirely satisfactorily with the preparations of the state of the art.
SUMMARY OF THE INVENTION
We have discovered a preparation for shrinkproofing wool which is storage stable, causes no yellowing in naturally colored or white wool, and leaves the treated wool in its original condition even after multiple launderings. At the same time, the hand of the treated wool or of knitted and woven fabrics, prepared from the wool, is not detrimentally affected.
The preparation of the present invention consists of
(a) 1 to 50 weight percent of organopolysiloxanes, which either consist, in the middle part of the molecule, of
(aa) 80 to 99.8 weight percent of units of the formula ##EQU1## (ab) 0.2 to 20 weight percent of units of the formula ##STR2## in the form of copolymers, or in which the siloxanes are present in the form of mixtures in each case of siloxanes with units of the formula (aa) and siloxanes with units of the formual (ab), in which the R 1 radicals consist of mercaptoalkyl or mercaptoaryl radicals to the extent of 0.03 to 3 mole percent and the R 2 radicals of hydrogen atoms to the extent of 5 to 50 mole percent, the remaining portion of R 1 and R 2 radicals being methyl radicals, of which, however, up to 10 mole percent may be replaced by longer-chain alkyl, aryl or hydrogen radicals, n has a value of 1.8 to 2.0 and m a valued of 2.0 to 2.5, and
(b) 50 to 99 weight percent of water.
Optionally, conventional emulsifiers and/or organic solvents and the usual additives may be added.
The simultaneous presence of siloxanes with mercaptohydrocarbon radicals and of silyl hydrogen atoms is an essential characteristic of the inventive process. It is at the same time possible to use either copolymers, in which the (aa) and (ab) units are present next to each other in the central part of the molecule, or mixtures of siloxanes in which the one component of the siloxane mixture contains (aa) units and the other component of the siloxane mixture (ab) units.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Especially preferred are preparations which contain organopolysiloxanes, in which the R 1 radicals consist of mercaptoalkyl or mercaptoaryl radicals to the extent of 0.1 to 0.5 mole percent, the remaining portion of R 1 radicals being methyl radicals.
Examples of mercaptoalkyl or mercaptoaryl radicals linked to the polysiloxane backbone are the mercaptomethyl, 2-mercaptoethyl, 3-mercaptopropyl, 3-mercaptoisobutyl or mercaptophenyl radical. The 3-mercaptopropyl radical is especially preferred.
A preferred inventive preparation is characterized by the fact that it contains organopolysiloxanes in which the R 2 radicals consist of hydrogen atoms to the extent of 36 to 48 mole percent, m has a value of 2.2 to 2.03 and the remaining portion of R 2 radicals are methyl radicals.
Especially preferred is a preparation which contains as siloxanes of the structure unit (ab), those of the formula ##STR3## in which p has a value of 3 to 50.
In particular, those siloxanes with (aa) units are preferred, in which n has a value of 1.990 to 1.998.
To the extent that they are not mercaptoalkyl or mercaptoaryl radicals or hydrogen atoms, the R 1 and R 2 radicals are methyl radicals. It is, however, permissible that up to 10% are replaced by longer-chain alkyl or aryl radicals. Examples of such alkyl or aryl radicals are the ethyl, propyl, dodecyl or phenyl radicals.
The preparation of copolymers with (aa) and (ab) units or of polysiloxanes which contain either (aa) or (ab) units is known from the state of the art. Organopolysiloxane units of formula (aa) may be prepared by first synthesizing polydimethylsiloxane diols having a viscosity of about 100 to 100,000 mm 2 /sec measured at 20° C. by emulsion polymerization, and especially by the cationic emulsion polymerization of low molecular weight cyclic polydimethylsiloxanes. These polydimethylsiloxane diols are then copolymerized with the desired amount of 3-mercaptohydrocarbon trialkoxysilane. Especially preferred, therefore, are preparations with the characteristics that they contain, as organopolysiloxane of the (aa) structure unit, those in which the mercaptoalkyl or mercaptoaryl radicals are linked terminally.
The preparation of silyl hydrogen-containing siloxanes is well known to those skilled in the art and can be accomplished, for example, by hydrolysis and condensation of the corresponding silanes.
The inventive preparation may be present in the form of an emulsion. It may, however, be used in the form of a solution in organic solvents.
The production of the inventive preparation in emulsion form can be accomplished in a known manner by emulsifying with the help of emulsifiers, for example, nonionic emulsifiers. These are obtainable by the addition of ethylene oxide and/or propylene oxide to compounds with an acidic hydrogen, for example, fatty alcohols, such as, lauryl alcohol or stearyl alcohol. Especially preferred are cationic emulsifiers, such as, for example, quaternary ammonium compounds, which have at least one longer-chain, hydrophobing radical attached to the nitrogen. For example, trimethyl lauryl ammonium chloride is a suitable emulsifier.
If the inventive preparation is to be used in the form of an organic solution, chlorinated hydrocarbons, such as, for example, 1,1,1-trichloroethane is preferred as solvent.
The preparation may contain the usual additives, such as, for example, optical brighteners, flame retardants, materials which affect the hand of textiles, fixatives, and fragrant substances.
Organopolysiloxane copolymers, which are suitable for the inventive preparations and contain units of formula (aa) and (ab), may, for example, have the following structures ##STR4## in which R 1 consists of mercaptopropyl radicals to the extent of 0.33 mole percent, the remaining R 1 radicals being methyl radicals.
Organopolysiloxanes, which are used in the form of their mixture may have the following structures: ##STR5## in which R 1 is as defined above.
The following examples show the production and formulation of suitable preparations as well as the properties of knitted fabrics treated with the inventive preparations, partly in comparison with known preparations.
EXAMPLE 1
To a reaction vessel are added 470 g of water, 3.3 g of didecyldimethylammonium chloride, 1.7 g dioctadecyldimethylammonium chloride, 3.5 g of a betaine of the formula ##STR7## and 10 g of a 1-molar potassium hydroxide solution and heated to 95° C. with stirring. Octamethylcyclotetrasiloxane (167 g, 0.56 moles) is added from a dropping funnel over a period of 45 minutes. After stirring the mixture vigorously for a further 1 hour, 2.95 g (0.015 moles) of 3-mercaptopropyltrimethoxysilane are added. After a further 30 minutes of stirring, the emulsion is cooled to 40° C. and its pH is adjusted to a value between 4 and 5 by the addition of 15 g of a 10% acetic acid solution.
The emulsion so prepared which is referred to in the following as emulsion A, contains 25 weight percent of an organopolysiloxane of formula (aa), in which the R 1 radicals are methyl radicals, of which, however, 0.33 mole percent are replaced by 3-mercaptopropyl radicals and n=1.993.
Furthermore, an emulsion referred to herein as emulsion B, composed of 25 weight percent of polymethylhydrogensiloxane of the formula ##STR8## is prepared with the help of 4 weight percent of an alkylaryltrimethylammonium chloride as the emulsifier and 71 weight percent of water in the customary manner, that is, with vigorous stirring.
By mixing the two components described above, the inventive storage-stable aqueous preparations listed below are obtained:
______________________________________ Weight Percent Weight PercentNo. of Emulsion A of Emulsion B______________________________________1 a 97.5 2.51 b 95.0 5.01 c 92.5 7.51 d 90.0 10.01 e 80.0 20.0 not of the invention1 f 100.0 0 not of the invention1 g 0 100.0______________________________________
The shrinkproofness and antifelting effects achieved with these preparations are described in the following application examples.
EXAMPLE 2
To an emulsifier solution the same as that of Example 1 and heated to 95° C., 146 g (0.492 moles) of octamethylcyclotetrasiloxane are added dropwise with vigorous stirring. After continuing the stirring for 1 additional hour and an interval of 30 minutes, 27 g (0.0975 moles) of methyldodecyldiethoxy silane and 2.7 g (0.0138 moles) of 3-mercaptopropyltrimethoxysilane are added dropwise and vigorous stirring once again is continued for a further 30 minutes. After cooling to 40° C., the potassium hydroxide which is contained in the emulsion, is neutralized by the addition of 15 g of a 10% acetic acid solution and, at the same time, the pH is adjusted to a value of 4 to 5.
The finely particulate aqueous emulsion contains organopolysiloxane units corresponding to formula (aa), in which the R 1 radicals are methyl radicals, of which, however, 2.36 mole percent are replaced by C 12 H 25 radicals and 0.33 mole percent by 3-mercaptopropyl radicals, and n=1.993.
From 90 weight percent of this emulsion and 10 weight percent of emulsion B from Example 1, a storage-stable, aqueous preparation in accordance with the invention is once again obtained simply by mixing.
EXAMPLE 3
(comparison example, not in accordance with the invention, corresponding to Example 2 of German Offenlegungsschrift No. 2,912,431)
To a solution of 5 parts by weight of hexadecyltrimethylammonium chloride in 67 parts by weight of water, a mixture is added which consists of 0.45 parts by weight of 3-mercaptopropyltrimethoxysilane and 25 parts by weight of octamethylcyclotetrasiloxane and which has been prepared in a separate vessel. After adjusting the pH of the mixture obtained to a value of 13 with potassium hydroxide, the mixture is passed twice through a colloid mill with an opening of 254μ.
The mixture is then heated for 3 hours at 80° C., cooled to 40° C. and allowed to stand for 10 hours, after which it is neutralized with hydrochloric acid. A turbid milky liquid is obtained.
EXAMPLE 4
(comparison example, not of the invention, corresponding to Example 2 of German Offenlegungsschrift No. 2,725,714)
A siloxane copolymer is prepared by heating together 7.5 parts by weight of CH 3 (CH 3 O) 2 Si(CH 2 ) 3 NHCH 2 CH 2 NH 2 and 1000 parts by weight of a polydimethylsiloxane with a hydroxyl group at each terminal silicon atom and a viscosity of about 4500 cSt at 25° C. Heating is carried out for 2 hours at 150° C. under nitrogen with vigorous stirring. The copolymer formed is a clear fluid with a viscosity of about 6000 mm 2 /sec at 25° C.
A copolymer (33.33 parts by weight), prepared as described above, is added to a mixture of 63.33 parts by weight of water, 1.42 parts by weight of Ethomeen S12, 0.24 parts by weight of Ethomeen S15 and 1.67 parts by weight of Tergitol TMN.6. The mixture is stirred rapidly to produce a siloxane-in-water emulsion (Emulsion C).
By the same procedure, an aqueous emulsion (Emulsion D) is prepared from 33.33 parts by weight of a polymethylhydrogen siloxane having terminal trimethylsiloxy groups and a viscosity of Ethomeen S12, 0.28 parts by weight of Ethomeen S15 and 1.67 parts by weight of Tergitol TMN.6 as emulsifiers. The amount of water used is 64.11 parts by weight and the pH of the emulsion is adjusted to a value of about 4.0 by the addition of acetic acid.
APPLICATION EXAMPLE 5
A material, knitted from a fine wool, is treated on a padder with the preparations described in Examples 1 to 4 but further diluted in such a way, that a solids add-on of 2% results after the impregnated knitted material is dried for 5 minutes at 140° C.
APPLICATION EXAMPLE 6
The fine woolen material is finished with preparation (c) of Example 1 by padding as well as by the exhaustion process in a laboratory winch dyeing machine. For this purpose, a knitted strip, weighing 200 g, is treated in a liquor consisting of 1.5 l water, 8 g of emulsion according to preparation 1 (c) and 8 g Na 2 S 2 O 5 .
After the temperature of the liquor is increased from 20° C. to 45° C., the active ingredients are exhausted up to 100% onto the wool within 15 to 20 minutes. After drying at 140° C. for a period of 5 minutes, the organopolysiloxane add-on is 2% based on the amount of fine woolen material used.
APPLICATION EXAMPLE 7
Water (360 parts by weight) in a large beaker is mixed consecutively with stirring with 2.7 parts by weight of emulsion C, 0.135 parts by weight of emulsion D from comparison Example 4, and 0.505 parts by weight of magnesium sulfate. The pH of the mixture obtained is adjusted to a value of about 5.5 by the addition of acetic acid. A piece of fine woolen material with the dimensions of 30×40 cm is then dipped into the liquid. The temperature of the liquid is increased slowly to 40° C. and the woolen material is moved around. In about 35 minutes, the liquid becomes clear, indicating deposition on the material. The material is then taken out, dried for about 6 minutes at 80° C. and exposed for 3 days to the ambient atmosphere (60% relative humidity, 20° C.).
APPLICATION EXAMPLE 8
Preparation (c) from Example 1, as well as a mixture of 92.5 weight percent of emulsion C and 7.5 weigh percent of emulsion D from comparison Example 4 are used 8 days after mixing for the treatment of the knitted fine woolen material. In this case also, the further diluted emulsions are padded onto the knitted woolen material in such a manner that, after drying by the procedure already described, the add-on of active ingredient is 2%.
Determination of Shrinkproofness
The shrinkproofness of the samples, treated in application Examples 1 to 8, is determined according to the recommendations of the International Wool Secretariat, Test Method 185. In this test method, samples of material are subjected to laundering for 3 hours in an International Cubex Machine. From the dimensions of the material before and after laundering, the area felting shrinkage can be determined from the formula ##EQU2## % L=percentage of shrinkage in length, % W=percentage of shrinkage in width.
The following values were obtained:
______________________________________ApplicationExample Preparation according to Example % AFS______________________________________5 1 a 9.5 1 b 5.5 1 c 0.5 1 d 2.5 1 e 11.0 1 f not of the invention 21.0 1 g not of the invention 37.0 2 3.0 3 Comparison Example 31.0 4 Comparison Example 12.06 1 c 1.07 4 Comparison Example 17.08 1 c 1.0 4 Comparison Example 27.0Untreated fine woolen material 45.0______________________________________
In contrast to the materials treated with the compositions of the present invention, the sample which has not been finished, revealed a strongly felted surface. In addition, the hand of the treated samples is significantly softer even after laundering than the hand of the untreated material before laundering. Moreover, in comparison with the sample which has been finished in application Example 5 with the preparation from Comparison Example 4, the inventively treated samples show no yellowing. | The invention relates to an aqueous preparation for shrinkproofing wool, which contains, as active ingredient, organopolysiloxanes of a particular structure with mercaptoalkyl or mercaptoaryl radicals and hydrogen atoms. The preparation is storage-stable and causes no yellowing in naturally colored or white wool. The hand of the wool is not disadvantageously affected. | 3 |
This application is a continuation of application Ser. No. 812,083, filed July 1, 1977.
BACKGROUND OF THE INVENTION
This invention relates to a line shock absorber which is engaged with a line intermediate its two ends in order to resiliently absorb shocks or jerks on the line such as occur in boat docking lines, tow lines and the like. It is also useful as a tensioning device to apply substantially constant tension to a line used as a cargo tie down on vehicles.
BRIEF DESCRIPTION OF THE DRAWINGS
The present invention is illustrated in FIGS. 1 through 4 wherein:
FIG. 1 is a side elevation of a preferred embodiment.
FIG. 2 is a top plan view of the device under strain imposed by tension in the line.
FIG. 3 is a longitudinal section taken along line 3--3 of FIG. 2, showing the absorber device under strain.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring to the drawing, 10 is a resiliently compressible member in the form of an elastomeric cylinder. In the embodiment shown, the cylinder 10 is hollow and sealed, although it may, if desired, be made of a homogeneous resilient material such as the various elastomeric sponge-like synthetic plastics which are available. Projecting generally radially outward from the axis of the cylinder 10 at each end thereof are flanges 12 and 14, each generally normal to the axis of the cylinder 10. Each flange is perforated to form an eyelet 16 and 18, respectively. A first line 20 passes through the eyelet 16 parallel to the cylinder axis and thence is wound spirally around the cylinder 10, as shown at 22. A second line 24 similarly passes through the eyelet 18 and is wound spirally around cylinder 10, as shown at 26. In practice it is preferred to constitute the two lines 20 and 24 as simply the two sections of a single integral line, the central portion of which is spirally wound around the cylinder 10.
When tension is applied to the line, which in toto will be referred to as line 28, the resilient cylinder 10 is strained in three modes simultaneously: twisting or torsion, bending, and squeezing or compression.
Since the line 28 is free to slide in the eyelets 16 and 18, the resultant force of the line on the eyelet, for example on the eyelet 18 and flange 14, is substantially as shown by the vector F1. Similarly, at the opposite end the force F2 is applied to the cylinder 10 at the flange 12. The radial components of F1 and F2 and the line coils around the cylinder constitute torsional couples which tend to strain the cylinder 10 in torsion, i.e. twist it, as shown in FIG. 2.
Since the flanges 12 and 14 are both offset from the axis of the cylinder 10 and on the same side thereof, the tension in the line 28 also produces a bending strain in the resilient body 10, as shown in FIG. 3. If the flange 14 is positioned diametrically opposite to flange 12, the bending strain is minimized, leaving the torsion as the principal strain in normal use.
Finally, since the line is wrapped around the body 10, which is elastomeric and compressible, the tension in the line 28 also squeezes the resilient body and produces a strain in that mode.
The aggregrate of these three strains constitutes, in the case of a tow or docking line, a shock-absorbing mechanism which minimizes the shock tension in the line 28 which would otherwise be experienced if a sudden jerk occurs on the line. Where the device is used as a tensioning mechanism, as in a tie down line, these strains apply a steady, relatively constant tension to the line.
The longitudinal component of the forces F1 and F2 being offset from the central axis of the resilient body 10, causes the bending shown in FIG. 3.
Where the device is to be used in and around the water, it is preferred to make it floatable, as for example by giving it a hollow interior, as shown in FIG. 3.
The proportioning of the device is not critical, such proportions being determined by the particular use to which the device is to be put. The specific device shown in FIGS. 1-3 has demonstrated quite suitable use as a shock-absorbing device in a docking line for boats, as for example for pleasure boats tied in a marina slip. In such case it has been found quite acceptable to make the cylinder 10 have a length-to-diameter ratio ranging somewhere from 3 to 6. The line 28 may be wound around the cylinder any number of times. In practice the number of spirals has ranged from one to five, although this, of course, is a matter of design preference.
As can be seen in FIG. 1, when the lines 20, 24 are in an unstrained position through the eyelets 12, 14, they are offset from the axis of the cylinder 10. This means that the elastomeric cylinder 10 can absorb a great deal of stress on the lines 20, 24 as tension tends to exert torsional, compressional and bending forces in an attempt to bring the two lines into alignment with the axis of the cylinder, as well as with each other. Further rotational movement of the eyelets 12, 14 allows free slippage of the lines 20, 24, reducing friction and wear on the lines. Prior art devices have the lines substantially along the axis of the cylinder thus reducing the amount of tension which can be absorbed by the cylinder as well as creating greater wear by the rubbing friction of the in-line eyelets which do not give much. In other words, the line shock absorber shown in FIGS. 1-3 has a great deal more give with less frictional wear and force caused by the eyelets allowing greater shock-absorbing capacity than any prior art devices.
By spiralling the line around the cylinder 10, the cylinder is caused to substantially retain its position on the line 28 by friction. By slackening the line 28, it may be readily slid along the line to a new position.
As intimated hereinbefore, the device has a wide range of uses, for example boat tie lines, fish lines, fishing net lines, tow line and shock cords generally. It may also be used for airplane tie down and for vehicle shock and tensioning cords on land, sea and air. Being floatable it will not be lost if accidentally dropped overboard. The floatation permits it to be readily used as an adjustable, but frictionally held, float in a swimming pool dividing rope, such as separates a pool into shallow and deep areas. In such case there is virtually no strain applied to the member, but the friction of the line around the cylinder retains it at a desired position. | A shock-absorbing line device comprising a resilient member, preferably in the form of a cylinder, around which a line is spirally wrapped, the two ends of the line passing through respective eyelets at each end of the cylinder. Shock on the line is absorbed by straining the cylinder in torsion and bending, and also compressing or squeezing the cylinder. | 5 |
SUMMARY OF THE INVENTION
[0001] The invention includes a process for recovering the liquids used in pretreatment of biomass for production of biofuels and other biomass based products. Liquid recovery and purification minimizes waste production and enhances process profitability.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
[0002] Disclosed herein is a process for recovering and purifying the liquids used for biomass pretreatment. Pretreatment is critical to increasing rates of saccharification before sugar conversion to bioproducts.
[0003] A wide range of materials have been utilized for pretreatment including acids (e.g., sulfuric acid), ammonia, carbon dioxide, organic solvents, and ionic liquids. Pretreatment opens the complex, recalcitrant structure of ligno-cellulosic materials by removing the lignin and hemi-cellulose layers that surround the crystalline cellulosic core. Pretreatment also opens the crystalline cellulose structure. After pretreatment, enzymatic saccharification occurs at dramatically higher rates which reduces processing times and equipment sizes.
[0004] To meet the targets for bioethanol production, large quantities of biomass must be processed. This will require large volumes of pretreatment chemicals. Process economics require special attention to the recovery and disposal of these materials. Ideally, pretreatment chemicals would be recovered, purified, and recycled thereby avoiding waste disposal. Additionally, water is used as a solvent throughout the process. Water usage is greater than pretreatment chemical usage so processes that permit water recycle are equally desirable.
[0005] Ionic liquids (ILs) offer a rapid, efficient solvent for pretreating biomass for saccharification. Exemplary ILs may be found, for example, in U.S. Patent Application Publication No. 20090011473 to Varanasi et al. The ILs may be categorized based on the structure of the cations or anions. Many of these ILs are effective in biomass pretreatment.
[0006] Recovery and recycle of pretreatment chemicals and water will require processes that can remove insoluble particulate matter and separate liquid mixtures of neutral species with a wide range of polarities. Membrane separation processes may be used effectively for these separations and in combination offer the potential for recycle of water and pretreatment chemicals. The proposed process incorporating membrane technology is described next.
Particulate Removal
[0007] Membrane filtration may be used to remove particulate matter ranging in size from microns to nanometers. Microfiltration, ultrafiltration, and nanofiltration processes remove progressively smaller material. A combination of these processes may be used to remove suspended particulate matter from spent processes streams prior to further purification and recycle.
[0008] Alternatively, electrodialysis processes permit removal of particulate matter from ionic pretreatment chemicals such as ILs. The ionic species pass through a series of cation and anion exchange membranes under the influence of an applied electric potential. In comparison to membrane filtration, electrodialysis may allow recovery of a greater percentage of the pretreatment chemical as we have demonstrated.
Liquid Separations
[0009] The pretreatment chemicals commonly are mixed with other solvents in the pretreatment process. Water is used primarily as the solvent during the pretreatment process but other fluids may be used including low molecular weight alcohols.
[0010] Thermal processes that separate fluids based on differences in equilibrium vapor pressure are used widely in the chemical process industry. Distillation effectively separates species with large differences in vapor pressure. However, it is less effective for mixtures of species with small difference in boiling points, form azeotropes, or show highly non-ideal solution behavior.
[0011] For these mixtures membrane separation processes based on differences in chemical potential offer unique advantages. The membrane selectively permeates one of the species to increases its concentration in the permeate. Membrane processes are not limited by equilibrium behavior and can be driven by using a sweep that increases the chemical potential driving force for transport across the membrane. Membrane modules are designed to provide efficient contacting between the feed and sweep.
[0012] Reverse osmosis may be used to concentrate pretreatment chemicals by selectively permeating water or other solvents. For example, reverse osmosis membranes possess a pore and chemical structure that inhibit the transport of IL ions relative to the solvent. However, our initial work indicates reverse osmosis membranes are not sufficiently selective to the solvent to permit high levels of IL recovery.
[0013] Membrane dehydration is an alternative for the recovery of pretreatment chemicals. In membrane dehydration processes, a sweep contacts a liquid feed across a membrane. The membrane permits selective transport of one component of the liquid mixture to the sweep.
[0014] Membrane dehydration is an attractive process for the recovery of IL from mixtures with water or other process solvents since ILs are non-volatile and cannot be removed by vaporization into the sweep. Experiments using aqueous IL mixtures confirm this.
[0015] Data obtained for water removal using an Osmonics RO AG membrane with a liquid feed of 30 ml/min and an air sweep feed rate of 15 L/min at a Temperature of 40° C. are given in Table 1. The data are presented as water removal rate as a function of IL concentration.
[0000]
TABLE 1
IL Concentration
Water Flux
(%)
(kg/hr/m 2 )
22.84
0.142
26.07
0.138
33.07
0.122
36.7
0.126
38.97
0.119
47.36
0.086
51.72
0.081
56.54
0.065
57.74
0.041
62.1
0.043
67.54
0.032
70.64
0.022
73.33
0.011
77
0.009
80.9
0.000
[0016] The water flux dropped to near zero at an IL concentration of ˜81%. This limitation arises from the use of compressed air that was not dehumidified. The presence of water vapor in the air sweep inhibits water transport across the membrane.
[0017] To remove water vapor a commercial air dehydration membrane was inserted in the line between the compressed air supply and the membrane module used for IL dehydration. Measured water removal rates as a function of IL concentration are reported in Table 2 for the same operating conditions as used to obtain the data in Table 1. However, the data in Table 2 was obtained using an Osmonics RO AK membrane instead of an AG membrane.
[0000]
TABLE 2
IL Weight
Water Flux
Concentration (%)
(kg/hr/m 2 )
64.30
0.052
73.01
0.030
75.50
0.015
81.60
0.008
83.50
0.006
85.90
0.000
[0018] Dehydration of the compressed air feed increases the maximum achievable IL concentration to ˜86%.
[0019] To further concentrate the IL, the compressed air flow rate through the air dehydration module was reduced. Reducing the flow rate decreases the water concentration of the dried air leaving the module. Data obtained for an air flow rate of 6 L/min are given in Table 3. All other experimental conditions are the same as for the data in Table 2.
[0000]
TABLE 3
IL Weight
Water Flux
Concentration (%)
(kg/hr/m 2 )
75.46
0.018
80.18
0.013
83.22
0.005
85.20
0.004
87.70
0.000
[0020] The maximum concentration increased slightly to −88%.
[0021] For the viscous IL-water mixtures used, the water concentration in the liquid adjacent to the membrane may decrease significantly due to concentration polarization. Increasing the liquid flow rate reduces concentration polarization and increases the water concentration at the membrane surface that drives transport across the membrane.
[0022] Table 4 indicates how water removal rates depend on IL concentration when the liquid flow rate is increased to 60 ml/min; all other experiment conditions are identical to those used to obtain the data in Table 2.
[0000]
TABLE 4
IL Weight
Water Flux
Concentration (%)
(kg/hr/m 2 )
88.92
0.0044
93.70
0.0043
94.68
0.0041
96.42
0.0031
96.86
0.0000
[0023] Increasing the liquid flow rate increases the maximum IL concentration to −97%. Optimization of liquid and gas flow rates may increase water fluxes further. No evidence for IL permeation across the dehydration membranes was found upon examination of the membranes after the dehydration experiments.
[0024] Any non-condensable gas may be used as this sweep. For example, helium, nitrogen, and argon may be used. The choice of sweep will depend on process economics.
[0025] Membranes for the processes described here may be produced in flat sheet, tubular, or hollow fiber shapes. The membranes may be formed from organic or inorganic materials that provide the required separation characteristics and are stable in the chemical and thermal environment of the process. Incorporation of the membranes in spiral wound or hollow fiber modules permits effective contacting with process streams.
[0026] Certain teachings related to liquid recovery and purification in biomass pretreatment processes were disclosed in U.S. Provisional patent application No. 61/259,537, filed Nov. 9, 2009, the disclosure of which is herein incorporated by reference in its entirety. | The invention includes a process for recovering the liquids used in pretreatment of biomass for production of bio-fuels and other biomass based products. Liquid recovery and purifications minimizes waste production and enhances process profitability. | 3 |
BACKGROUND
A typical color camera separately monitors red, green, and blue components of an image. Electronic imagers rely on some means of separation of the illumination incident on the sensor into a number of spectral channels. Widely-used means of discrimination between spectral components of the imaging scene include the Color Filter Arrays (usually employed in systems based on single focal plane array) and beam-splitting prisms (primarily employed in systems based on multiple focal plane arrays). In either case, the incident illumination is separated into a small number, usually 3 or 4, discrete color (spectral) channels.
For any given scene, the exact ratio of color channel values will depend on the spectral characteristics of the entire optical stage of the imager. This is typically done using a color filter array over a photosensitive area. The color filter array is formed of a plurality of different colored elements, which respectively pass only color of a predetermined spectral parameter.
A typical color filter array is shown in FIG. 1A . Each of the boxes such as 100 represents a single pixel. Each set of four boxes outlined by the line 102 can be considered as a megapixel. The pattern in the megapixel repeats throughout the entire color filter array grid.
Spectral channels of the modern color imagers do not have the same spectral sensitivities as color-sensitive elements, the cones, of the human eye. FIGS. 1B-1D respectively illustrate the spectral sensitivity curves of the human eye (β, γ, ρ) and spectral transmittances of the red, green and blue color channels typical for modern RGB electronic imaging systems. As a consequence, the direct use of individual color channels values of the imager as stimuli for typical display devices, such as VGA or NTSC monitors, does not lead to correct color rendition. Hence, colors are corrected color signals detected by the electronic imaging system into color channel stimuli appropriate for the output to the image rendering device.
Each megapixel 102 has two green filters, one red filter, and one blue filter. This is because the eye is usually more sensitive to green than it is to red and blue.
The intent of the filter of FIG. 1A is to provide an image which is precisely matched to the spectral content of the eye. However, this filter, while it does the best that it can, is not precisely matched. It is often desirable to interpolate between the values.
For example, the value received at area 100 is only indicative of the green portion impinging on area 100 . However, some part of that incoming light is also red. Another part of the incoming light is also blue. Hence, each of the pixels is processed according to a transformation to solve the equation:
R=K 11 R+K 12 G+K 13 B
G=K 21 R+K 22 G+K 23 B
B=K 31 R+K 32 G+K 33 B
This transformation completely defines the system. This includes the so-called color transformation matrix:
K 11 K 12 K 13 K 21 K 22 K 23 K 31 K 32 K 33
SUMMARY
The inventor recognized from the above, however, that this corrects only for red, green, and blue parts of the image. The actual red, green, and blue colors look good. The other colors are not corrected quite as well.
The present system corrects the signal for all of a plurality of desired colors. This is complicated, however, by the fact that one only has control over red, green, and blue.
According to the system as disclosed herein, the operation is broken down into a number of colors, e.g., 24 colors. The camera is used to detect a color chart or a chromaticity chart which has the 24 colors of interest. Each detected color is compared with a reference color. The coefficients of the color coefficient matrix are adjusted to make each of those colors approach the reference color more exactly. Another aspect weights the colors so that the most important colors obtain more correction.
BRIEF DESCRIPTION OF THE DRAWINGS
The patent or application file contains at least one drawing executed in color. Copies of this patent or patent application publication with color drawing(s) will be provided by the Office upon request and payment of the necessary fee.
These and other aspects of the invention will be described in detail with respect to the accompanying drawings, wherein:
FIG. 1 shows a prior art megapixel system used in a color filter array;
FIGS. 1A-1D illustrate the sensitivity of the eye to different colors;
FIG. 2 shows a basic setup of the system of the present embodiment; and
FIG. 3 illustrates a typical calibration chart.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
The conventional techniques to determine the coefficients Kij of the color correction matrix are based on analyzing the image of color calibration chart with N distinct color elements. In order to calculate a color correction matrix from the image of the color calibration chart, the appropriate stimuli Yi, suitable for driving a given image rendering device, must be known for each element of the chart from an independent experiment. Such color measurement techniques are, for example, specified by the Commission on Illumination (CIE). Each of N distinct elements of the calibration color chart Yi are known. Xi are determined based on imaging of the chart. The coefficients of the color correction matrix solve N 2 linear equations or solve N equations for each chart element.
Color correction matrix obtained by this technique provides for correction of color rendition of all N colors used in the process, provided that the colors could be physically displayed by the image rendering device and that they are within the spectral sensitivity range of the imaging system.
Even though the color correction matrix obtained by this approach provides for good rendition of the N colors used in calibration, other target colors are not rendered correctly.
In fact, in many real imaging systems once the basic colors (such as red, green and blue in RGB systems) have been calibrated, the white elements of the scene appear as pink or blue. To counteract this effect, many electronic imaging systems employ white balancing techniques subsequently to color correction. White balancing algorithms aim at achieving good rendition of white color by adjusting (dynamically or statically) the gains on individual color channels. This procedure, in effect, modifies the coefficients of the color correction matrix. However, modification of the color correction matrix inevitably leads to deterioration of the rendition quality of the basic colors used in color calibration. For example, in RGB systems, the good quality of rendition of white is achieved at the expense of somewhat arbitrary degradation of red, green and blue. In extreme cases, white balancing may lead to the situation where only white color is rendered correctly and most other colors are visibly distorted.
In general, it is difficult to achieve “perfect” color rendition across the entire visible spectrum using electronic imaging system with finite number of color channels. Since the spectral sensitivities of realistic imaging systems and the human eyes do differ at every wavelength, every color representable by the image rendering device would have to be corrected individually. For example, a VGA monitor with 24 bits per pixel (8 bits per color channel) would require color correction matrix with 2 24 rows to achieve the best possible color rendition.
This system selects a number of colors including at least the primary colors (3), white, and at least 1-20 other colors, preferably at least 3 others. This generates the N×N color correction matrix for any given N-channel imaging system that would yield the best possible compromise in quality of the rendition of the large numbers of colors, as opposed to perfecting rendition of N colors at the expense of others. All of these colors must be balanced.
The preferred setup is shown in FIG. 2 . A color chart 200 has thereon a plurality of desired colors. While the preferred embodiment uses 24 colors, any number could be alternately used. Any number of colors, greater than the three primary colors (red, green, and blue or cyan, magenta, yellow) could be used. A video camera 202 obtains an image of the color chart 200 , which is processed in the image processor 204 . Preferably those other colors include at least white, and at least three other preferred colors, but more preferably the other colors include 20 other colors total for a total of 24 colors.
Image processor 204 compares each detected color with a reference color.
The color calibration chart has a number of distinct color elements corresponding to the colors that are deemed important for overall good color rendition of the electronic imager. For an N-channel imager, the proposed technique does not impose any limitation on the number of colors to be optimized, as long as the calibration table contains at least N+1 distinct color elements. The color channel stimuli Yi appropriate for the given image rendering device (such as RGB values for VGA monitor) should also be known for each color element of the calibration chart from an independent experiment.
The techniques for characterizing the calibration chart are beyond the scope of the present disclosure. There is a number of commercially-available and well known color calibration charts characterized by their manufacturers in accordance with standard techniques set by standard-defining organizations such as Inter-Society Color Council at National Bureau of Standards (ISCC) and International Commission on Illumination (CIE).
In order to generate an optimal color correction matrix 206 , the calibration chart 200 is imaged under illumination conditions similar to those that will be used during normal operation of the imager. Once the image of the chart is obtained, the detected signal values of each color channel Xi of the imager are recorded for all color elements of the calibration chart.
For each of the colors to be corrected, three least-squares fits are carried out. The least-squares fits are done for each of the primary colors; here, red, green, and blue. An error signal G E is obtained by taking the square of the difference between Gn′ (what one expects to see for the green color) subtracted from the G actual (what one actually sees). Similar operations are done for red and blue.
The mathematical representation of this operation is shown in Equation 3.
( Gn ′[what expect to see]− G C [actual]) 2 =G E
( Rn′−R C ) 2 =R E
( Bn′−B C ) 2 =B E (3)
The goal of this technique is to minimize G E , R E , and B E for all of the 24 colors, all for all of the desired colors for which correction is to be carried out. The coefficients in the color correction matrix of Equation 2 are adjusted in order to minimize the 24, three-item sets. This can be done by trial and error, or by solution using linear equations to dynamically change all the values until the best mix is reached. The minimization can be expressed mathematically as
min C k 1 , C k 2 , … , C K ∑ J = 1 M [ ( ∑ i = 1 N C ki · X 1 J ) - Y 1 J ] 2 → C k 1 , C k 2 , … , C kN ; k = 1 , … N
where K is the number of the color channel currently being calibrated, M is the number of color chart elements used for calibration, and N is the number of the color channels in the imaging system.
Hence, this system adjusts all the values until making the best compromise.
A second embodiment notes that color calibration based on Equation (2) results in the color correction matrix that yields comparable quality of color rendition for all colors in the calibration chart. However, the distortion of some colors impacts subjective image quality more than the distortion of other “less important” colors. For example, poor color rendition of white, gray and skin colors is more noticeable than poor rendition of blue and yellow parts of spectra.
This embodiment, therefore, modifies the color calibration process to attach more importance to some colors at the expense of the others. In the context of proposed least-squares based method, the ability to prioritize colors is achieved by using weighting coefficients multiplying individual color deviations.
Therefore, in this embodiment, the color correction matrix is evaluated based on minimization of the weighted sum of squares of differences between detected color channel values Xi and corresponding stimuli Yi across entire set of color elements of the calibration chart as follows:
min C k 1 , C k 2 , … , C K ∑ J = 1 M [ ( ∑ i = 1 N C ki · X 1 J ) - Y 1 J ] 2 W j → C k 1 , C k 2 , … , C kN ; k = 1 , … N
where Wj is the weight given to the color of the j-th element of the calibration color chart.
This uses the equations shown in Equation 4.
( Gn′−G c ) 2 ·W i =G E
( Rn′−R c ) 2 ·W i =R E
( Bn′−B c ) 2 ·W i =B E (4)
Where I is between 1 and 24 and each of the I's representing a different color, this second embodiment adds a weighting factor W i . Each color is weighted according to its importance in seeing an image the way the eye expects to see the image. Practically speaking, red, green, and blue are extremely important, white is important, skin color and gray scale are also important. Unimportant ones are brown and other dull colors. All of the rest are medium importance.
Since this system takes care of all colors simultaneously, one obtains the best possible trade-off between all of the different possibilities.
A preferred mode uses a 3-color RGB Bayer pattern color filter assembly. The system uses 24-color GretagMacbeth ColorChecker chart marketed by GretagMacbeth, New Windsor, N.Y. as the color calibration chart. GretagMacbeth describes their chart as “Checkerboard array of 24 scientifically prepared color squares in a wide range of colors. Many of these squares represent natural objects of special interest, such as human skin, foliage and blue sky. These squares are not only the same color as their counterparts, but also reflect light the same way in all parts of the visible spectrum. Because of this unique feature, the squares will match the colors of natural objects under any illumination and with any color reproduction process.
This preferred mode assigned higher weights to chart elements corresponding to red, green, blue and human skin elements as well as a number of greyscale elements.
FIG. 3 shows an exemplary ColorChecker chart.
Another aspect of the present specification is the approach to white balance procedures in conjunction with use of the color correction matrix generated by described above method. As mentioned in the Background, the conventional approach to white balancing is to adjust the pre-computed color correction matrix so that the image areas corresponding to white colors appear white. This is usually done by adjusting individual gains on the color channels of the imager to achieve equality of all color components for white areas of the image. However, the byproduct of this procedure is that the quality of the color rendition for colors used during calibration of the color correction matrix is being somewhat arbitrarily compromised. In contrast, the color correction method disclosed here results in optimal balance between quality of rendition of white as well as other important colors that were given high weights during color calibration. Thus optimal white balance is “built-in” the color correction matrix and does not require further adjustments as long as the spectra of the illumination does not change.
Another important reason for using dynamic real-time white balancing in imaging systems is to compensate for possible changes in the illumination spectra. From this point of view, dynamic white balancing will be beneficial to systems calibrated according to the present invention as well. However, since the initial color correction matrix determined from Equation (3) already provides white balance under the same illumination spectra as was used for calibration, the traditional methods of dynamic white balancing should be modified.
In systems calibrated in accordance with the present system, the aim of the dynamic white balancing is to keep ratios of the color channels of the imager at white areas of the image equal to the ratios of the same color channels measured for white image areas in the same illumination conditions as existed during calibration. This approach allows to dynamically compensate for changing illumination spectra without favoring the quality of rendition of white at the expense of other colors.
Although only a few embodiments have been described in detail above, those of ordinary skill in the art will understand that modifications are possible without departing from the teaching noted above. | A system of correcting for color filter array by correcting for a plurality of colors in the color filter array. A color correction matrix is formed which corrects each color for a plurality of desired characteristics simultaneously. These desired characteristics can include, for example, all 24 colors in a chromaticity chart. An additional aspect includes weighting the more important colors relative to the less important colors. | 7 |
BACKGROUND OF THE INVENTION
The present invention relates to a flexible tubular pipe which can be preferably used in deep-sea applications, for depths of between 1000 and 3000 m, although it can also be used for depths of less than 1000 m. Such flexible tubular pipes are used in subsea oil production installations for transporting fluids such as hydrocarbons.
The present invention relates to a flexible tubular pipe which can be preferably used in deep-sea applications, for depths of between 1000 and 3000 m, although it can also be used for depths of less than 1000 m. Such flexible tubular pipes are used in subsea oil production installations for transporting fluids such as hydrocarbons.
Several types of flexible tubular pipes are used at the present time and are described in API (American Petroleum Institute) 17 J. In certain flexible pipes, there is a pressure vault which consists of a helical winding with a short pitch of a shaped wire which may be self-interlockable or interlockable by means of a fastener. Likewise, the metal carcasses used in flexible pipes called “rough bores” are formed from a crush-resistant doubly interlocking profiled metal strip.
In all cases, it has been attempted to improve the moment of inertia/weight ratio of the interlocked strips or shaped wires used for producing the various metal layers of the flexible pipes.
For deep-sea applications and in the case of pressure vaults, the reinforcing wires must have a high moment of inertia in order to withstand the external pressure and a low weight in order to reduce the total weight of the flexible pipe so as to improve the performance of the pipelaying means and allow the flexible pipe to be self-supporting.
Several solutions have been proposed.
A first solution has consisted in using a shaped wire, the cross-section of which is in the form of an I, as described in FR-A-2 782 142. Such a shaped wire has an acceptable moment of inertia/weight ratio but the manufacturing cost is very high because of the fact that it is obtained by rolling or wire drawing.
Another solution is described in FR 2 654 795. The internal carcass is formed from doubly interlocking metal strips, by making a flat metal tape, such as a stainless steel strip, undergo plastic deformation in order to give it the shape of a doubly interlocking profiled strip, and then by spiraling the profiled strip, that is to say winding it helically with a short pitch with interlocking of the profiled metal strips. After two consecutive turns have been interlocked, a final plastic deformation of the strip is carried out in order to complete the interlocking.
In Patent FR 2 665 237 it is recommended to produce a tubular metal carcass comprising at least one box section wound in a helix with a short pitch, said metal carcass being obtained by means of two complementary profiled strips wound helically with a short pitch. Many examples of profiled strips are described and shown in that document, some of which, such as for example those in FIGS. 8 and 9 , consisting of a strip in the form of an elongated S and having a box section at a first end and an upwardly curved fastening edge at the other end, the fastening edge penetrating a dish formed by the box section and the transverse bar of the of the preceding turn. The curved fastening edge may rest on the bottom of the dish ( FIG. 9 ) or it may not be in contact with said bottom ( FIG. 8 ).
It should be noted that all the cross-sections of the box sections provided at one or both ends of each profiled strip are square or rectangular cross-sections.
Although such box-section profiled strips have been satisfactory, they have been found to have certain drawbacks. When one considers that a box section is formed by parts of the same turn of the profiled strip and comprises an upper wall, a lower wall and side walls and when an external force is applied to one of the upper and/or lower walls, such as a compressive or crushing force or else a force generated by the underpressure fluid, buckling of the side walls or faces and/or the upper or lower walls of the box section may then occur, thereby reducing, at least locally, the crush resistance of the internal carcass.
For forces or pressures exceeding a certain value, buckling of the side walls of the box section occurs.
For lower forces or pressures and when the side walls are not strictly perpendicular to the upper and lower walls of the box section, crushing of said box section may occur, resulting in the side walls moving further apart or closer together (opening or closing of the box section). To prevent this opening or closing phenomenon, it has been recommended in certain cases such as, for example, in FR 2 665 237 to weld one end of the box section at one point on the strip. However, such a solution increases the manufacturing cost and it is difficult to implement.
In a prior embodiment, the box-section strip adopts the shape of a pair of spectacles. This profile is produced from a strip whose free edges are welded to this same profile so as to give the profile good stability for laying. However, the welding operation is difficult to implement and considerably increases the manufacturing cost.
In another prior embodiment, the spectacles-shaped profile is similar but produced from two tubes, of square cross-section, said tubes being joined together by a strip which is welded to these tubes. The welding operations again considerably increase the manufacturing cost.
In addition, these various shapes of the profile do not make it possible to limit the creep of an adjacent sealing sheath. It is sought to prevent such creep as far as possible, mainly in the case of the pressure vault. It should also be noted that no information is provided regarding the width/thickness ratio of the strip, although this has become important in order to ensure stability of the profile during pipe laying, so as to prevent the buckling effect.
This is because if the profile has too large a width with respect to its thickness, the side walls of the box section will buckle during spiraling or winding with a short pitch.
In French Patent No. 2 808 070, the profiles that are described give good results but sometimes have drawbacks, especially because of the great lack of symmetry of the profile.
SUMMARY OF THE INVENTION
The object of the present invention is to provide a profile which makes it possible to simplify the spiraling operations while still having a high moment of inertia/pitch ratio, similar to that obtained with conventional shaped wires of equivalent height, and a high moment of inertia/weight ratio which is needed in particular for great depths.
The subject of the present invention is a flexible tubular pipe comprising a metal box section spiraled in a helix about a longitudinal axis of said flexible pipe and it is characterized in that the box section consists of at least one interlocked hollow profiled tube.
The invention can be carried out in order to produce a pressure vault or a carcass with an interlocked tube of any cross-section.
One advantage of the present invention lies in the fact that an inexpensive tube is used which is profiled, for example, using a roll train or a die to the desired shape. In this way it is possible to optimize the moment of inertia of the profile, and therefore to improve the moment of inertia/weight ratio, and-to give it a shape suitable for the interlocking of the winding turns to be carried out simply and without any difficulty.
Another advantage of the present invention is that it is no longer necessary to provide a system for holding the box section, which in the prior art is produced by stopping or welding it, which simplifies the manufacture, for example, of the pressure vault produced using the tube according to the invention, so that the manufacturing cost is considerably reduced.
Another advantage is that the moment of inertia/winding pitch ratio is optimized, it being possible for the interlocked profile tube to limit the influence of the necessary gap between the turns in order to give the pipe a certain flexibility.
Another advantage lies in the fact that the hollow profiled tube is approximately symmetrical and in that the compression regions compensate for the tension regions. In this way, the winding or spiraling is easier to implement.
Further advantages and features will become apparent on reading the description of several embodiments of the invention and the appended drawings in which:
FIG. 1 is a schematic sectional view of a pressure vault produced by the helical winding of at least one hollow profiled tube according to a first embodiment of the invention;
FIG. 2 is a schematic sectional view of a pressure vault produced by the helical winding of at least one hollow profiled tube according to a second embodiment of the invention;
FIG. 3 is a schematic sectional view of a pressure vault produced by the helical winding of at least one hollow profiled tube according to a third embodiment of the invention;
FIG. 4 is a schematic sectional view of a pressure vault produced by the helical winding of at least one hollow profiled tube according to a fourth embodiment of the invention;
FIG. 5 is a schematic sectional view of a pressure vault produced by the helical winding of at least one hollow profiled tube according to a fifth embodiment of the invention;
FIG. 6 is a schematic sectional view of a pressure vault produced by the helical winding of at least one hollow profiled tube according to a sixth embodiment of the invention;
FIGS. 7 , 8 , 9 and 11 are schematic sectional views of a hollow profiled tube according to different embodiments of the invention; and
FIGS. 10 and 12 are schematic sectional views of a pressure vault produced by the helical winding of at least one hollow profiled tube according to another embodiment.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
The term “interlocked” is understood hereafter to mean either a profile that is not interlockable, but which would be interlocked by one or more fasteners, or an interlockable profile or a self-interlockable profile.
In the embodiments shown in FIGS. 1 to 5 , the hollow profiled tubes are not interlockable and therefore require one or two fasteners of suitable cross-section in order to link two consecutive turns of the same winding together when a single hollow profiled tube is used or of two windings when two hollow profiled tubes are used. Such non-interlockable profile tubes may be compared with hoop reinforcements well known to experts and described in API 17 J.
The hollow profiled tubes 1 and 2 may each have a trapezoidal cross-section, as shown in FIG. 1 , the trapezoidal cross-section being obtained, for example, from a tube of circular cross-section which has been deformed by a roll train or in a die. Each tube is helically wound about the longitudinal axis A-A of the flexible pipe, which has not been shown but which is described according to the various types in the API 17 J. To produce a pressure vault, the two tubes 1 and 2 are wound or spiraled with a short pitch. The two tubes 1 and 2 of the two consecutive turns 3 and 4 are joined together or fastened by means of a first fastener 5 which goes around the lower faces 6 and 7 of the tubes 1 and 2 . The fastener 5 has an approximately U shape. The consecutive turns 4 and 8 are interlocked by means of a fastener 9 , similar to the fastener 5 , but going around the upper faces 10 and 11 of the tubes constituting the next turns. The turn 12 is interlocked with the previous turn 8 by a lower fastener 5 , whereas the turn 12 and the next turn 13 are interlocked using an upper fastener 9 .
Preferably, the lower fasteners 5 and the upper fasteners 9 have arms 5 ′ and 9 ′ which are inserted sufficiently into the interstices or gaps 14 between the turns, so that good interlocking is achieved.
In the embodiment shown in FIG. 2 , the hollow profiled tubes 21 and 21 ′ are similar to those represented in FIG. 1 , but the fastener between two consecutive turns is obtained by means of different fasteners.
Each hollow profiled tube 21 , 21 ′ is housed in contact in a horizontal part 20 of a fastener 22 , which has two lateral flanges or horizontal parts 23 , 24 located at an upper level with respect to the lower level occupied by the part 20 . The flanges 23 , 24 have ends 25 , 26 bent over downward in order to allow interlocking with another U-shaped fastener 27 . The turn 21 ′ bears on the fastener 27 and is held in place by the contact on the ends 26 and 25 of the fastener 22 , which may be regarded as adopting the shape of a double S.
In the embodiment shown in FIG. 3 , the hollow profiled tubes 30 have a trapezoidal cross-section and two consecutive turns 31 and 32 are interlocked by means of fasteners 33 , each having an end 34 which is raised and then bent over downward, and the other end 35 is simply raised upward, so that two fasteners 33 interlock via their ends. In the left-hand part of FIG. 3 , the hollow profiled tube 30 nearly bears on the two ends 34 of two consecutive fasteners, whereas the tube 30 of the turn 32 bears on the end 34 , but is away from the end 34 of the other fastener. The pressure vault must have a certain gap between the turns in order to give the pipe a certain flexibility, FIG. 3 showing the vault with a minimum pitch (left-hand part) and with a maximum pitch (right-hand part) with the turns 32 and 36 further away.
In the embodiment shown in FIG. 4 , the fasteners 40 and 41 are identical and each fastener 40 , 41 has an elevated part 42 made between an upwardly curved end 43 and a bulge 44 of upwardly turned concavity, the turn 45 being placed on the part 42 and bearing on the end 43 and the bulge 44 . The low part 46 of the fastener 40 accommodates the elevated part and the associated turn of the other consecutive fastener 41 , as shown in the figure.
In the embodiment shown in FIG. 5 , the fasteners 50 adopt the shape of a zeta, each turn 51 being placed between the upper arms 52 and lower arms 53 of the consecutive fasteners.
In the embodiments shown in FIGS. 6 to 11 , the hollow profiled tubes are interlockable or self-interlockable and may be compared with the interlockable shaped wires well known to experts, such as U-, Z- or T-shaped wires.
In the embodiment shown in FIG. 6 , each hollow profiled tube 60 of a turn 61 is also trapezoidal in shape, but with a flat horizontal upper face 62 and a lower face 63 which is deformed toward the upper wall so as to create, on the one hand, a kind of bulge 64 for the interlocking by means of an approximately U-shaped fastener 65 , and, on the other hand, to define two hollow regions 66 and 67 .
In the embodiment shown in FIG. 7 , the shape of the approximately T-shaped hollow profile 70 has an upper wall 71 which is deformed at two points in order to produce two bulges 72 and 73 , the lower wall 74 being horizontal.
In the embodiment shown in FIG. 8 , the cross-section of the hollow profiled tube 80 is a zeta, and therefore is self-interlockable with another profile tube of the same cross-section. The right-hand part differs from the left-hand part by the fact that the upper wall 81 has a deep bulge 82 which is in contact with the lower wall 83 .
In the embodiment shown in FIG. 9 , the bulges 91 and 92 of the upper wall 93 are deep and in contact with the lower wall 94 so as to stiffen the profile. In this way, three separate box sections 95 to 97 are defined, in order to improve the crush strength. This is also applicable to the embodiment shown in FIGS. 6 and 8 in which the bulge or bulges may be deep and brought into contact with the opposed wall.
The embodiment shown in FIG. 10 differs from that shown in FIG. 6 by the fact that the upper face 100 is also deformed in order to constitute a bulge 101 directed toward and in contact with the bulge 103 on the lower face 102 . In this way, a “butterfly” shape is produced, comprising two box sections 104 and 105 separated from each other. This “butterfly”-shaped profile has the advantage of providing two smaller volumes and of consequently increasing the resistance to the external pressure. In addition, since the upper wall of each box section 104 , 105 is shorter, the risk of buckling is reduced.
The profile according to the invention shown in FIGS. 10 and 12 consists of a metal tube 1 which is bent so as to form the separate box sections 104 , 105 which are symmetrical with respect to a vertical axis of symmetry B-B. The box sections 104 , 105 are separated by an upper bulge 120 and a lower bulge 121 . The tube portion which constitutes the bottom of the lower bulge 121 lies approximately in the plane of the neutral fiber 17 and the upper bulge 120 bears on said tube portion, said portion forming a contact region 122 for the upper and lower walls of the tube after deformation.
Each box section, which preferably has a trapezoidal cross-section, has side walls 123 , 124 which are inclined and make an angle α greater than 60° and less than 90° with the horizontal C, which corresponds to a generatrix of the flexible pipe. Since the upper bulge 120 and lower bulge 121 are on the contact region 122 , which lies approximately on the plane of the neutral fiber 17 and therefore in an approximately central region of the profile, said region will therefore be subjected to few stresses during spiraling and will not work very much. This greatly improves the stability and the performance of the profile.
For an angle α close to 90°, the profile is stronger and for an angle α close to 60° the profile is more stable. Consequently, the optimum angle α is a compromise between strength and stability.
The profile described above can be used for producing a pressure vault or the metal carcass, when the flexible pipe has one, by winding it in a helix, with a short pitch, about the horizontal axis A-A of the flexible pipe, each turn of the winding consisting of a pair of box sections. Since the profile is not self-interlockable, it is possible to interlock the turns in several ways.
The first way of interlocking is shown in FIG. 10 . In this embodiment, the turns of the winding of the profile are interlocked from below, that is to say the fasteners 12 ′, for example in the form of an inverted U, have their arms 13 ′ and 14 ′ placed in the consecutive lower bulges. Another interlocking is shown in FIG. 12 and it consists in using the same fasteners, but referenced 12 , which have their arms 13 and 14 placed in the consecutive upper bulges. In the latter case, interlocking is obtained from above, as opposed to the previous way which is called interlocking from below.
Another method of interlocking, also shown in FIG. 12 , consists in interlocking the turns from above and from below, with upper fasteners 12 whose arms 13 and 14 are placed in the upper bulges and lower fasteners 12 ′ whose arms 13 ′ and 14 ′ are placed in the lower bulges.
The upper and/or lower fasteners may advantageously have, in the gap 125 between two consecutive turns, a bulge or hump, not shown, which makes it possible to increase the local moment of inertia of the fastener. The fastener, stiffened at the hump, is more resistant to the internal pressure of the fluid flowing in the flexible pipe. Creep of the inner sealing sheath, owing to the effect of the internal pressure, applies a high contact pressure on the fastener. Moreover, to improve the technical characteristics of the fastener, the radii of curvature of the hump correspond to those of the profile so as to allow the functional clearances of the vault to be maintained. To increase the burst strength of the pressure vault owing to the effect of the internal pressure flowing in the flexible pipe, it is possible to use the properties of the fastener. Since the resistance to the internal pressure depends in part on the cross-section and on the mechanical properties of the material used, all that is required is to increase the thickness of the fastener or to choose a material having high mechanical properties, preferably properties superior to those of the profile; the vault-fastener pair will have a higher burst strength.
It is also possible to use means for reducing the creep of an impermeable inner polymeric sheath which bears on the profile. These means may comprise, by themselves or in combination, a rod, which may be placed in the lower bulges, and/or a shaped wire, which covers the gap between two consecutive turns. The shaped wire may be flat or have the shape of an inverted T, the vertical arm of the T fitting into the gap. The shaped wire may also be an anticreep woven strip like that described in FR 2 744 511. These means for reducing the creep of a sheath may be provided above the profile when it is interlocked from below and when a polymeric sheath is placed above the profile. It should be noted that the rod may also be placed in the upper bulges.
Another advantage lies in the fact that since the interlocking is carried out in the box section, the moment of inertia/pitch ratio of the profile is thus optimized while eliminating the regions of low moment of inertia.
The embodiment shown in FIG. 11 relates to the special shape of a hollow profiled tube 110 whose upper wall 111 and lower wall 112 are deformed at two points with bulges 113 , 114 and 115 , 116 , respectively, the bulges 113 and 115 being in contact with each other while the bulges 114 and 116 are in contact with each other. Three separate box sections 117 , 118 and 119 are thus made. The depth of the bulges 113 to 116 depends essentially on the technical characteristics that it is desired to obtain.
All the profiles shown in FIGS. 1 to 11 must not exceed a certain width L so that the hollow profiled tubes can be wound helically. This is because if the profile is too wide, during winding the forces will be too high and there would be a risk of them making the side walls of the profile buckle. The profile must therefore have a maximum width L which depends, on the one hand, on the thickness e of the tube and, on the other hand, on the height H of the profile. Tests carried out have shown that the results are satisfactory when:
0.5 <L/H <5 and preferably 1 <L/H <3 L/e <20.
By producing a shaped wire from a hollow profiled tube, a more compact tube-fastener pair is obtained, thereby optimizing the moment of inertia/winding pitch ratio. As a consequence, the performance of the pressure vault produced in one of the embodiments described above is increased. The measurements carried out show that, for a profile 20 mm in height and 3 mm in thickness, the moment of inertia/effective pitch ratio is 260 mm 3 whereas the same ratio for a strip box-section profile, 20 mm in height and 3 mm in thickness, is 210 mm 3 .
For a profile of the type shown in FIGS. 10 and 12 , use is made of a metal tube 2.5 mm in thickness and with a perimeter of 120 mm, which is bent so as to obtain a profile 20.4 mm in height and 38 mm in width. The slopes of the side faces of the profile are 80° to the horizontal. With such dimensions, a moment of inertia/pitch ratio of 250 mm 3 is obtained.
As regards the moment of inertia/weight ratio, it was found that this was of about 1.6 with profiles of the present invention, which represents an increase of 20% compared with known lightened profiles and 60% compared with shaped wires. The present invention thus achieves two objectives, namely a reduced manufacturing cost and an increase in the moment of inertia/weight ratio for deep-sea use in which it is necessary to withstand high external pressures.
Depending on the application of the hollow profiled tubes described with reference to FIGS. 1 to 12 , it is possible to place inside said tubes an electrical conductor which can be used for possibly heating the fluid flowing in the flexible pipe, by the skin effect or by the Joule effect, by the induction effect, etc.
It would also be possible to place rods or other tubes transporting a heat transfer fluid in the upper and lower bulges of the profiles illustrated in FIGS. 10 and 12 .
In addition, the fastening may be effected from above the winding turns or from below, or else from above and from below, depending on the dynamic or static use of the flexible pipe. One advantage of interlocking from above and below is that it makes it possible to limit the creep of the internal and/or external plastic sheaths. It is also possible, when necessary, to fill the bulges with a filling material so as to limit the creep of said plastic sheaths.
At the bulges of the various profiles, it will be attempted to limit the creep by optimizing the height of the bulge.
The present invention also relates to a process for manufacturing the flexible pipe, in which at least one of the metal reinforcing layers, such as the pressure vault or the metal carcass, is formed by a helical winding about the longitudinal axis of said flexible pipe of at least one interlocked hollow profiled tube having one of the cross-sections shown in FIGS. 1 to 11 . Preferably the cross-section of the hollow profiled tube is approximately trapezoidal.
It should also be noted that it is possible to produce a simultaneous winding of at least two profile tubes, oriented in opposite directions, so that the side walls of the adjacent turns are parallel. This would allow the moment of inertia/pitch ratio to be increased. | A flexible tubular pipe comprising a metal carcass helically coiled about a longitudinal axis of said flexible pipe and the carcass comprises a seamed profiled hollow tube. | 5 |
CROSS-REFERENCE TO RELATED APPLICATION
The present application is a continuation-in-part of application Ser. No. 827,983 filed on Aug. 26, 1977, now abandoned.
FIELD OF THE INVENTION
The present invention relates to monorail-type passenger vehicles, and more particularly, the present invention relates to monorail type vehicles having some means for raising and lowering the vehicle from an elevated position adjacent the underside of a monorail to a lowered position at street level. The present invention is particularly suited for police patrol work in large metropolitan cities or alternatively as public transport conveyances in rapid transit systems.
BACKGROUND OF THE INVENTION
It is known that in densely-populated cities, such as Philadelphia, New York, Chicago, etc. police patrols using automobiles is of limited effectiveness because of the tendency for patrol cars to become bogged-down in traffic, thereby being unable to respond promptly to emergency situations. It should be apparent, therefore, that an emergency type vehicle which can carry passengers in an elevated position along the underside of the monorail located above a city street, or along a street surface, is particularly suited for police work. This is because, in its elevated position, the vehicle can travel at high rates of speed above the traffic and is, therefore, able to cover substantial distances in short periods of time. When the vehicle arrives at its intended location, it can be lowered to street level, either for riding along the street, or for stopping to load or unload passengers. Needless to say, such a vehicle used in densely populated metropolitan areas would increase police effectiveness with less manpower. Preferably, such a vehicle, if used for police patrol work, should be highly maneuverable and lightly armored for protection of the police and have as standard equipment a rotatable turret for observation and/or for use of fire arms, if necessary.
Such a vehicle as described above must be capable of accelerating and decelerating rapidly. Since acceleration and deceleration forces can create substantial stresses on various parts of the vehicle, the vehicle of the above type must be capable of withstanding such stresses in order to insure the safety of the passengers. Moreover, the vehicle must be capable of being raised and lowered rapidly, even while in motion.
OBJECTS OF THE INVENTION
With the foregoing in mind, it is a principal object of the present invention to provide a new and improved overhead monorail vehicle having a gondola which may be raised and lowered.
It is another object of the present invention to provide simple yet reliable means for raising and lowering a gondola between a retracted position adjacent the underside of the monorail and an extended position adjacent street level.
A further object of the present invention is to provide a new and improved rail and drive wheel design for a monorail type vehicle to insure that the vehicle does not derail at operating speeds.
A further object of the present invention is to provide a monorail type vehicle which is specifically designed for police patrol work in congested areas of large cities.
Yet another object of the present invention is to provide apparatus which provides an efficient and economical means of affording police protection and patrol in large cities.
A still further object of the present invention is to provide a means for increasing the police coverage in high crime areas of large cities without necessitating an increase in police manpower.
SUMMARY OF THE INVENTION
As a more specific object, the present invention provides apparatus for transporting people rapidly either along a ground surface or in an elevated position adjacent the underside of a monorail, or at various intermediate levels. The apparatus includes a monorail, motorized carriage mounted on the monorail, a gondola disposed below the monorail carriage, and means connecting the gondola and the carriage to raise and lower the gondola relative to the carriage even while the carriage is in motion. The raising and lowering means includes an elongated fixed-length boom which is pivotally connected at one end to the carriage and which has a free end mounting a series of links and hydraulic cylinders which are connected to the aft end of the gondola. A main hydraulic cylinder connects the boom to the carriage and pivots the boom from a retracted position extending along the underside of the carriage to an extended position depending substantially vertically downward therefrom. Control means in the gondola causes the main hydraulic cylinder to cooperate with the links and other hydraulic cylinders for raising and lowering the gondola. Cooperating hooks are mounted atop the gondola and to the boom for interengaging one another when the boom is in its uppermost position and the gondola is fully retracted.
BRIEF DESCRIPTION OF THE DRAWINGS
The foregoing and other objects, features and advantages of the present invention should become apparent from the following description when taken in conjunction with the accompanying drawings, in which:
FIG. 1 is a front elevational view of a monorail vehicle embodying the present invention, the view illustrating the vehicle in its retracted position;
FIG. 2 is a side elevational view of the vehicle illustrated in FIG. 1, but not illustrating monorail support stanchions;
FIG. 3 is a side view, in reduced scale, of the vehicle illustrated in FIG. 2, but illustrating the gondola in its lowermost extended position at street level;
FIG. 4 is a partially-sectioned, enlarged front view of the carriage portion of the vehicle illustrated in FIG. 1;
FIG. 5 is an enlarged sectional view of one of the pair of motor drive-transmission units of the carriage illustrated in FIG. 3;
FIG. 6 is an enlarged fragmentary view of the gondola latching mechanism illustrated in FIG. 2, the view illustrating the rigid mounting of the gondola hook member to the top of the gondola; and
FIG. 7 is a view, similar to FIG. 6, but illustrating a modified latching mechanism.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring now to FIGS. 1-3, it may be seen that the present invention provides a monorail type vehicle which is designed to run along a horizontally disposed track 1 connected at spaced intervals to a series of arms which extend outwardly and upwardly from stanchions such as illustrated in FIG. 1. The rail or track 1 supports a carriage from which a gondola 16 is suspended. In the illustrated embodiment, the carriage comprises a chassis 3 and axle frames 12 and 13 which ride on shock absorbing devices 14 and 15. The axle frames and the chassis are connected by means of linkages L (FIG. 2), and a plurality of grooved wheels 4, 5, 6, 7, 8 and 9 (FIG. 2) mount the carriage to the rail 1.
Motive power for the carriage is provided by specially-designed electric motors 10 which are mounted to the chassis 3 and connected to the wheels 4-7 via suitable drive mechanisms such as illustrated in FIGS. 4 and 5. Preferably, all motors are driven simultaneously to accelerate the carriage along the track 1 and, as the carriage speed increases, selective motors are shunted out by means of suitable controls contained in motor control center 54 mounted atop the chassis 3. At cruising speed, the monorail vehicle is thereby capable of operating with a minimum of power input.
The rail 1 is provided with a special shape for mating with the grooved wheels 4-7 to support the carriage on the rail 1. Wheels 8 and 9 engage the underside of the rail 1 and act as guides to prevent derailment of the carriage at designed speeds of the vehicle. As may be seen in FIGS. 2 and 4, the axle support members 12 and 13, and the carriage chassis 3, overhang one side of the rail 1. Preferably, the rail 1 is fabricated by rolling it into the illustrated "I" shape. Thus, the bottom and top grooved wheels grip the rail 1 and cooperate to absorb lateral movement to eliminate the need for special appurtenances which otherwise would be required for this purpose.
As best seen in FIG. 2, the gondola 16 has a fuselage shape with an observation dome or turret 56 which is mounted adjacent its upper forward end and which may be provided with gun ports if the vehicle is used for police patrol work. Preferably, the gondola 16 mounts a series of seats enabling it to carry a series of passengers. At the lower forward end of the gondola 16, wheels 19 and 20 are provided to allow the gondola to be driven along a street surface directly under the rail 1 either intentionally or in the event of a failure of the hydraulic system. As will be discussed, a latching mechanism 55 is provided to mechanically interconnect the gondola 16 to the boom 21 when the gondola 16 is in its uppermost elevated position.
For the purpose of raising and lowering the gondola 16 relative to the carriage, a series of hydraulic cylinders and links are provided to form an articulated connection therebetween. To this end, the forward end of the chassis 3 has a depending appendage 23 which pivotally mounts the forward end 22 of a first elongated member or boom 21. The boom 21 is of a predetermined fixed length and extends rearwardly from the appendage 23 along the underside of the chassis 3 substantially parallel to the rail 1 when the gondola 16 is in its uppermost position as illustrated in FIG. 2. The boom 21 is pivoted in a clockwise direction about its pivot point 22 by means of a hydraulic cylinder and piston assembly 31,32. The upper or rear end 39 of the cylinder 31 is pivotally connected to an appendage 47 at the bottom rear of the chassis 3, and the second or lower terminal end 40 of the piston 32 is pivotally connected to the boom 21 by a bearing 48 located adjacent the pivotal connection 22 of the front end of the boom 21 to the chassis appendage 23. Thus, extension and retraction of the piston 32 in a well known manner causes the boom 21 to pivot either clockwise or counterclockwise about its pivot point 22 in a manner to be described.
The rear or second end 26 of the boom 21 pivotally mounts a generally triangular shaped second link member 24 to pivot about a bearing 25 located at a first vertex thereof. A generally rectangular shaped third link member 27 is pivotally secured adjacent its upper rear end corner 28 to a third vertex bearing 29 located below and rearwardly of the vertex 25 at the free end 26 of the boom 21. A second end 30 of the rectangular member 27, located diagonally-opposite the end 29, is pivotally connected to the upper rear end of the gondola 16.
The link members 24 and 27 are pivoted relative to one another and the gondola 16 as the boom 21 pivots from its retracted position illustrated in FIG. 2 to its extended position illustrated in FIG. 3. To this end, a series of second, third and fourth hydraulic cylinder and piston sets 33, 34; 35, 36; and 37, 38, respectively, are provided. Each of the cylinder and piston sets have spaced opposite first and second ends such as the ends 41 and 42; 43 and 44; and 45 and 46, respectively, the first end being at the mounted end of the cylinder and the second end being at the free end of the piston.
In order to pivot the link 24, the first end 41 of the second hydraulic cylinder set 33, 34 is pivotally affixed to the boom 21 at a second point 49 which is located intermediate the first bearing point 48 where the main cylinder piston 40 is connected and the second or free end 26 of the boom 21. The second end 42 of the second cylinder and piston set 33, 34 is pivotally secured to a point 50 of the triangular link member 24 intermediate the vertices 25 and 51 thereof.
The first end 43 of the third piston and cylinder set 35, 36 is pivotally secured to the third vertex 51 of the second traingular link or support member 24 rearwardly of the free end of the boom 21. The second end 44 of the third piston and cylinder set 35, 36 is pivotally secured to a second corner 52 of the third support or link member 27. The first end 45 of the fourth piston and cylinder set 37, 38 is pivotally secured to a third corner 53 of the third support or link member 27. The second end 46 of the fourth piston and cylinder set 37, 38 is pivotally secured to the top 17 of the gondola 16 adjacent its midsection.
A control console 57 is located in the front of the gondola 16 and is provided for the purpose of actuating the various piston and cylinder sets for operating the motors 10 to drive the carriage along the rail and to raise and lower the gondola 16 relative to the rail 1.
As noted heretofore, the gondola 16 is positively latched in its uppermost retracted position, and to this end, the latching means 55 is provided. As best seen in FIG. 6, the latching means 55 comprises an upstanding hook-shaped latch member 55a which is rigidly secured at its lower end 55c to the top 17 of the gondola 16 adjacent its midsection. A hook 55b is provided on the bottom of the boom 21 adjacent its pivot point 22, and the hook 55b functions to interengage the latch member 55a in the manner illustrated in FIG. 2 for securing the gondola 16 in its retracted position.
The operation of the hydraulic piston and cylinder sets will now be described. The various hydraulic piston and cylinder sets are connected in a well-known manner by hydraulic hoses to an hydraulic pump mounted in the gondola 16. The pump is controlled by a switch provided in the control console 57. When the gondola 16 is in its retracted position illustrated in FIG. 2, the switch is normally off, and the pump is deactivated with the various hydraulic piston and cylinder sets locked in the positions illustrated in FIG. 2.
In order to cause the gondola 16 to descend from the retracted position illustrated in FIG. 2, the various hydraulic piston and cylinder sets are operated sequentially at various rates of speed to effect the desired unlatching of the latch mechanism 55 and the consequent descent of the gondola 16. The sequencing of hydraulic cylinders by varying their rates of extension and retraction is well known to those skilled in the art of designing hydraulic control cylinders. However, by way of further elucidation, it is noted that in the present invention, when the gondola 16 is in its retracted position, the piston and cylinder set 31 and 32 is fully retracted, while all of the other piston and cylinder sets are fully extended. To begin the descent of the gondola 16, the hydraulic pump is actuated to cause the piston and cylinder set 31 and 32 to begin to extend. Such extension causes the boom 21 to pivot about its pivot point 22 in a clockwise direction (FIG. 2) with the latching means 55 still interengaged through an included angle of 15° of boom movement. Thereafter, the piston and cylinder sets 33, 34; and 35, 36 begin to retract causing the rectangular link member 27 to pivot counterclockwise about its pivot point 29. Simultaneously, the piston and cylinder set 37, 38 begins to retract to cause the front end of the gondola 16 to pivot clockwise about its pivot point 30 at its rear end until the latching mechanism 55 disengages. Piston and cylinder sets 31, 32; 33, 34; and 35, 36 continue their respective retractions but at a faster rate to cause the gondola 16 to descend while the piston and cylinder set 37, 38 retracts at a rate which is sufficient to keep the gondola 16 nearly level through the balance of its descent.
In order to raise the gondola 16 from its fully extended position, as is illustrated in FIG. 3, the various piston and cylinder sets are sequenced and actuated at various speeds in basically a reverse of the aforementioned procedure. For instance, in the fully extended position, piston and cylinder set 31, 32 is fully extended; piston and cylinder sets 33, 34; and 35, 36 are fully retracted; and piston and cylinder set 37, 38 is partially retracted. To raise the gondola 16, the piston cylinder set 31, 32 is initially caused to retract followed by a simultaneous actuation of the piston and cylinder sets 33, 34 and 35, 36 to extend at a faster rate than the piston and cylinder set 31, 32 is retracting. Piston and cylinder set 37, 38 then extends at a rate sufficient to keep the gondola 16 in a generally horizontal position as pivot center 53 rotates about the pivot center 29. In the course of raising the gondola 16, the four piston and cylinder sets cause the gondola 16 to move rearwardly in a nearly horizontal position to about half of the distance between street level and the retracted position below the track 1. At this location, the piston and cylinder set 37, 38 retracts further to cause the front end of the gondola to tilt upward about 30° relative to the horizontal. This upward tilt of the front end of the gondola causes the fixed latch member 55a on the top of the gondola 16 to clear the arc of travel of the hook 55b on the boom 21 while continued actions of the piston and cylinder sets 31, 32 and 33, 34 and 35, 36 operate until the boom 21 is in its horizontal position. Thereafter, the piston and cylinder set 37, 38 extends fully to interengage hooks of the latching mechanism 55. After the latching mechanism 55 has been engaged, the switch on the control console 57 is turned off to deactivate the hydraulic pump.
While the upward tilting motion of the front end of the gondola 16 during latching and unlatching of the latch means 55a and 55b is not likely to be disturbing to regular passengers, there may be installations in which an entirely horizontal motion of the gondola 16 from its fully retracted position to its fully extended position is desired. In order for the gondola 16 to be maintained horizontal at all times between its fully retracted and fully extended positions, it is necessary for the hooks to engage and disengage one another with a minimal amount of pivotal motion of the boom 21 about its pivot point 22. For this purpose, as best seen in FIG. 7, a latch member 155a is pivotally secured to the top 17 of the gondola 16 at about its midsection to pivot about a horizontal axis A. An hydraulic cylinder and piston set 160, 161 is connected to a lower extension 155c of the latch member 155a and operates when extended and retracted to pivot the latch member 155a about its pivot axis A which is mounted to the gondola 16 as by a clevis. As a result, the hydraulic piston and cylinder set 160, 161 may be fully extended during the horizontal upward motion of the gondola 16 to insure clearance between the hooks until such time as the boom 21 is substantially horizontal whereupon the hydraulic cylinder and piston set 160, 161 can be retracted to cause the hooks 155a and 155b to interengage one another and effect the desired latching action. The cylinder and piston set 37, 38 may then be extended slightly to ensure positive hook contact before the hydraulic pump is turned off. Uplatching is effected by reversing this process, preferably after the cylinder and piston set 37, 38 have been retracted slightly to cause the tips of the hooks 155a and 155b to clear one another when the cylinder and piston set 160, 161 is extended. See the dotted line position in FIG. 7.
The present invention as set forth hereinbefore has a number of advantages. First of all, by utilizing a series of relatively rigid link members and hydraulic cylinders, the gondola 16 is capable of being raised and lowered rapidly even while moving at substantial speeds. Moreover, since the boom 21 is disposed substantially parallel to the track 1 when the gondola 16 is in its retracted position, the forces of acceleration and deceleration are taken up in tension and compression of the boom 21. By virtue of the interengaged hook and latch member, the entire assembly is fail safe, since if the main hydraulic piston and cylinder set 31, 32 were to fail, the boom 21 would simply pivot about its pivot point 22 and the gondola 16 would remain safely in an elevated position above the street level. Failure of any of the other cylinders would be of no effect as long as the latching mechanism is engaged.
In view of the foregoing, it should be apparent that the present invention now provides an improved high speed monorail type vehicle which is particularly suited for use in highly congested city areas.
While a preferred embodiment of the present invention has been described in detail, various modifications, alterations and changes may be made without departing from the spirit and scope of the present invention as defined in the appended claims. | A monorail type vehicle which is particularly suited for high speed travel on a street or at various locations above a street. The vehicle comprises a motor driven tandem wheel carriage engaging an overhead monorail and a gondola suspended from the carriage by means of an elongated boom having one end pivotally and hydraulically connected to the carriage and having a free end mounting a series of hydraulic cylinders and links operatively connected to the rear of the gondola for raising and lowering the gondola as desired. | 1 |
BACKGROUND OF THE INVENTION
The present invention relates to a telephone set including a circuit for seizing the line to which it is connected without lifting the handset off the gravity switch.
Normally a telephone user seizes the line to which the telephone is connected simply by lifting the handset off the telephone. This simple act operates a "gravity" switch on which the handset is supported, and contacts of the gravity switch loop the telephone line. The exchange then feeds power to the telephone via the pair of wires which also serve to convey speech and signalling such as dial pulsing. Once the line is looped so that current can flow, the telephone becomes unavailable for receiving calls from other telephones (it becomes "engaged"), and it is connected to exchange equipment for receiving instructions from the user.
Telephone sets are increasingly being equipped with electronic circuits, and in particular with microprocessors, which need to be powered from the telephone line before they can be used. However, such telephone sets include sets associated with various terminals such as telecopiers, or modems, or directory interrogation devices which may well be used without the user ever wanting to speak into the telephone. The simplest way of "turning on" a telephone set so that it can be used with such a terminal is simply to lift the handset off its gravity switch and then rest it on some other support. This solution is not entirely satisfactory: firstly there is the problem of sounds being picked up by the microphone which may be embarassing to the user or which may interfere with operation of the terminal, or both; and secondly there is a considerable risk that the user will forget to replace the handset, in which case an excessive telephone bill may result, and the telephone set and its associated terminal are prevented from receiving incoming calls, since the microprocessor is incapable of replacing the handset itself.
The present invention therefore provides a telephone set which is capable of seizing its telephone line without the handset being lifted off the gravity switch.
SUMMARY OF THE INVENTION
The present invention provides a telephone set for connection to a telephone exchange over a telephone line comprising a pair of line wires, the telephone set including: a handset; a gravity switch operated by lifting said handset to seize a telephone line connected to the telephone set by looping said line; a microprocessor and associated electronic circuits requiring DC power for their operation; a diode bridge connected to draw power from a looped telephone line connected to the telephone set and to supply said microprocessor and associated electronic circuits with DC at a predetermined polarity regardless of the polarity of the wires of the telephone line; said bridge being connected to said microprocessor and associated electronic circuits via a power supply network including a common return wire; the improvement wherein the telephone set further includes a circuit for seizing the telephone line by looping the line without lifting the handset off the gravity switch, said circuit including a user-operable call switch having line seizing contacts connected on the line side of the diode bridge in parallel with line seizing contacts of the gravity switch, a relay having line holding contacts connected in parallel with said line seizing contacts of the gravity switch and of the user-operable call switch, and a line release transistor connected in series in said common return wire and capable of connecting and of disconnecting said common return wire from said diode bridge, said microprocessor being connected to control said relay and said release transistor, and being programmed to respond to a user operating said call switch and thereby initially seizing said line by operating said relay to hold the line loop, and to subsequently release the line by turning off said release transistor before releasing said relay, said relay being released after current has ceased to flow in the telphone line, thereby protecting the relay's line holding contacts from being damaged by current surges in the line during release thereof.
BRIEF DESCRIPTION OF THE DRAWINGS
An embodiment of the invention is described by way of example with reference to the accompanying drawings, in which:
FIG. 1 is a block diagram of a telephone set in accordance with the invention and including a microprocessor and equipped with an on-hook line seizing circuit;
FIGS. 2A and 2B are circuit diagrams of the on-hook line seizing circuit and of parts of the telephone set associated with its operation.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
The telephone set 1 shown in FIG. 1 is connected to an exchange (not shown) via two line wires L1 and L2. In conventional manner, the line wires are suitable for feeding direct current (DC) to the telephone set 1 from the exchange and for providing a communication path between the telephone 1 and the exchange, and hence between the telephone 1 and other telphones which can be reached via the exchange.
The telephone set 1 comprises a ringer unit 2 for indicating when other telephones are calling the set 1, a key pad unit 3 for enabling a user to set up a call to another set and to signal other requirements to the exchange, and an audio unit 4 for performing two-way conversion between signals in a form suitable for being conveyed on the line wires L1 and L1 and signals useable by the telephone user, whether man or machine.
A logic unit based on a microprocessor 5 together with a plurality of auxiliary circuits co-ordinates operation of the set 1, at least when it is used as a telephone.
A line seizing circuit 6, which constitutes one of the auxiliary circuits mentioned above serves to retain the line for a user of the telephone set for the purpose of making a call to another set via the line wires L1 and L2.
The unit 4 is usually referred to as the audio circuit, and includes a conventional handset having a microphone and an earphone. It may further include a loud speaker (not shown) enabling several people to listen to a call simultaneously, and/or a modem (not shown) for transmitting data which may be displayed on a display unit. The unit 4 sends and receives suitable signals over the line wires L1 and L2 to which it is connected when a call is established.
The unit 2 is usually referred to as a ringer, and is connected to the line wires L1 and L2 upstream from the other components of the telephone set, and in particular upstream from the seizing circuit 6 which serves to isolate the components of the telephone set other than the ringer 2 from the line whenever the telephone set is not being used for an established call or for setting up a call. A relay RE is operated whenever a call is in progress or is being set up and has a normally closed contact re2 which serves to isolate the ringer unit 2 whenever the relay RE is in its working position and to reconnect the ringer unit 2 whenever the relay RE returns to its rest position. A conventional protective component 7 is provided across the line wires L1 and L2, since the ringer unit 2 may be a bell set including diodes to prevent tinkling, or an electronic ringer which actuates the telephone set's loud speaker. The unit 3 may comprise a dial, but is preferably a push button key pad. It is connected to the microprocessor 5 via an interface circuit (not shown) which feeds power to the unit 3 and which monitors it in such a manner as to enable a user to enter data concerning telephones to be called or operation of the telephone set 1 itself.
Other auxiliary circuits assist the microprocessor 5, both in its own operation, eg. a memory circuit 8, and in the application which it controls, eg. a signalling unit 9 which may generate dial pulses or multifrequency tones for setting up calls through the exchange to which the telephone set 1 is connected.
A power supply unit 10 supplies power to the power consuming units of the telephone set 1 via power rails symbolised by wires VA and M which are connected to the positive and negative terminals respectively of a diode bridge 11 which determines the direction in which DC power is applied to the telephone set regardless of the polarities of the wires L1 and L2 from which it draws the power. The diode bridge 11 feeds a regulator circuit 12 which matches the DC supplied by the bridge 11 to the requirements of the units powered thereby, and which regulates the supply of power as a function both of load and of a system of priorities. The regulated DC is applied to a regulated positive power rail VD.
The user of the telephone set 1 sets up a call by means of the seizing circuit 6 which may be actuated either by taking the handset off hook or by pressing a user-operable call switch in the form of a push button T while leaving the handset on hook.
Taking the handset off hook operates a gravity switch having two sets of springs cc1 and cc2, with the set cc1 serving to loop the line. A circuit 13 serves to activate (reset) the microprocesser 5, but effective activation is delayed by a power supply monitoring circuit 14 until the power supplied by the unit 10 meets the requirements necessary for proper operation of the microprocessor 5.
The spring set cc2 is connected via wires 1cc to the microprocessor 5 to signal the fact that the telephone handset is off hook.
If the button T is pressed while the handset is on hook, the line is likewise looped to supply power to the telephone set because the button T has a contact t1 connected in parallel with the spring set cc1 of the gravity switch.
Either way, once the telephone set is powered up, the microprocessor 5 is reset by the circuit 13 as soon as the monitoring circuit 14 is satisfied that the power supply is adequate.
The microprocessor then controls the line seizing relay RE in the unit 6 to cause its normally open contact set re1 to close in parallel with the gravity switch spring set cc1 and the contact t1 of the button T. The relay RE is preferably a miniature bistable relay so as to be compatible with the electronic circuits of the telephone set. The closed contact set re1 loops the line L1, L2 and the button T may be released. An extra set of contacts (not shown) of the relay RE is used to inform the microprocessor 5 of the state of the relay thereby enabling the microprocessor to inform the user that the button T can be released. This information may be conveyed in various ways, eg., via a loud speaker or via a display unit if the telephone set is equipped with either.
Once the line is looped even though the handset is still on hook, it is necessary to provide means for releasing the relay to open the contacts re1 and hence open the loop.
Opening the loop generally induces a vigourous current surge because of the line inductance, and there is a relatively high risk of welding together the contacts re1 if the relay RE is a miniature relay chosen for its compatibility with the electronic components of the telephone set.
To avoid this happening, the line seizing circuit 6 is provided with a seizure release switch unit 15 (preferably a transistor) which is under the control of the microprocessor 5 and capable of being turned off to open circuit the power supply loop inside the telephone set 1 at the end of a call.
The release transistor 15 is connected between one end of the return power supply rail M and the negative terminal C of the diode bridge 11 in such a manner as to be able to isolate the negative terminals of the circuits connected to the rail M from the negative terminal C of the diode bridge 11.
Since the release transistor 15 turns off the power supply to the circuits in the telephone set and in particular to the logic circuit which includes the microprocessor 5, an auxiliary power supply is provided which operates at least temporarily to ensure that the bistable relay RE is released after the loop has itself been released so that the contacts re1 return to their normally open configuration.
The auxiliary power supply is preferably in the form of smoothing capacitors (not shown) which are connected across the terminals of the circuits involved and in particular across the microprocessor.
FIGS. 2A and 2B are circuit diagrams showing a particular embodiment of the various components of a line seizing circuit and the associated circuits in the telephone set.
The lines wires L1 and L2, the gravity switch contact sets cc1 and cc2, the contact set re1 of the relay RE, the contact t1 and microprocessor starting contact t2 of the button T and the diode bridge 11 are all shown in FIG. 2A.
In the embodiment shown, the diode bridge 11 has AC terminals A and B connected to the line wires L1 and L2 has three DC power supply outlets E, F and G together with a common return C. This is done by connecting four pairs of series connected diodes 64 to 71 across the AC terminals A and B.
The power supply terminals E, F and G are all at the same positive voltage, but they power different components of the telephone set as a function of their various roles, and they enable said components to be selectively powered independently of each other should that be necessary.
The microprocessor 5 is powered from the terminal G via a regulator circuit 122 in the power supply unit 10.
The regulator circuit 122 is connected to the positive terminal G of the diode bridge, and to its common return terminal C via wires m and then M, and then via the release transistor 15.
The regulator circuit 122 is brought into action by a line voltage check circuit 123 and its regulator voltage is determined internally by a regulator 16 having its outlet fed back to its control input. The regulated power supply rail is the rail VD.
A reset circuit 124 starts the microprocessor 5 once the power supply voltage is adequate, as measured across the terminals of a capacitor 51.
Once sufficient voltage is applied to the line voltage monitoring circuit 123 which is connected between the positive terminal F of the diode bridge and the wire m, a line current flag CC is applied to an interrupt input of the microprocessor 5 by means of suitably connected NPN and PNP transistors 54 and 57 respectively, together with their associated bias resistors 52, 53, 55, 56 and 58.
The line current flag CC is simultaneously applied to the regulator circuit 122 to control the base of an NPN transistor 23 via a diode 18 and a resistor 17. The base of the transistor 23 is also connected to the regulator 16. The transistor 23 controls a main power regulating PNP transistor 22 having its collector connected to feed current to the regulated positive power rail VD, its emitter connected to the unregulated positive power supply terminal G via a low value resistor 21, and its base also connected to the unregulated terminal G via a bias resistor 20 and a decoupling capacitor 19. The voltage on the rail VD is detected by a potential divider made up of two resistors 26 and 29 which control the base of an NPN transistor 24 which shares an emitter resistor 27 with the transistor 23, and which has its collector connected to the unregulated rail G. The transistors 23 and 24 constitute a long-tail pair controlling the flow of current through the power regulating transistor 22 in such a manner that the regulated rail VD remains at a constant voltage from the negative rail m.
A power supply smoothing capacitor 51 with a value of about 220 microfarads is connected between the regulated rail VD and the negative wire m to maintain power to the microprocessor 5 during short interruptions, eg. during loop-disconnect dialling.
Once there is voltage on the regulated rail VD, a transistor 30 having its base connected to the rail VD via a resistor 31 and its emitter connected to the emitters of the long-tail pair 23 and 24 via a resistor 25 is turned on. The collector of the transistor 30 is connected to turn on a Darlington-connected pair of transistors 32 and 34 which acts as a constant current source between the unregulated rail G and a timing capacitor 41 in the reset circuit 124. The arrangement serves to charge the capacitor 41 in substantially the same time lapse regardless of the length of line to which the telephone may be connected.
The reset circuit circuit 124 is necessary because the microprocessor 5 is powered only while the telephone set in which it is installed is being used. When it is turned on anew, it must be forced to start by executing instructions from a specific point in its program.
The reset input RAZ of the microprocessor 5 is initially connected to low voltage via an NPN transistor 39 which has its emitter connected to the low voltage rail m and which has both its base and its collector connected to the regulated rail VD via respective resistors. The base of the transistor 39 is also connected to the collector of an NPN transistor 38 which is connected to be switched on by the Darlington pair 32, 34 supplying sufficient current to a pair of resistors 36, 37 connected in series with a diode 35. However, said series connection of resistors 37, 36 and the diode 35 is connected in parallel with the timing capacitor 41, and initially when the Darlington pair is turned on, nearly all the current therefrom flows into the timing capacitor 41 and insufficient flows through the resistors to turn on the transistor 38 and hence to turn off the transistor 39. After a suitable lapse of time, the voltage on the capacitor 41 rises to a point where the reset condition is removed from the microprocessor 5, which is then free to execute its program.
An NPN transistor 42 is connected connected across the terminals of the timing capacitor 41 to provide means for discharging it. The base of the transistor 42 is connected to the positive terminal F on the diode bridge via a diode 45 in such a manner as to ensure that the capacitor 41 is discharged each time the telephone set is re-connected to the exchange.
An NPN transistor 46 can be used to short circuit the base of the transistor 42 via the diode 45 from the moment a voltage appears at the diode bridge terminal F. A wire CGA connects the microprocessor 5 to the base of the transistor 42 downstream from the diode 45 and enables the microprocessor 5 to inhibit further resetting.
After the call button T for seizing the line has been pressed, the relay RE is operated by a relay control circuit 125 under the control of the microprocessor 5, ie. after it has itself been suitably powered up, and has started running its program. A signal PLE is provided for this purpose and is applied to the base of an NPN transistor 59 which is connected between the terminal F and the low voltage wire m via a resistor 62 to bias a pair of complementary transistors 61 and 60. The emitters of the complementary transistors 61 and 60 are connected together and to one terminal of the winding of the relay RE via a capacitor 63. The other terminal of the relay winding is connected to the low voltage rail m as is the collector of the PNP transistor 60, while the collector of the NPN transistor 61 is connected to the unregulated rail F.
When the transistor 59 is turned on under the control of the microprocessor 5, it turns off the transistor 60 and it turns on the transistor 61, thereby discharging the capacitor through the winding of the relay RE. Conversely, turning the transistor 59 off causes the capacitor 63 to be charged through the transistor 61 and the winding of the relay RE. Thus the capacitor 63 ensures that the winding is fed with pulses.
The various circuits shown in FIG. 2A shown to be powered by the diode bridge comprise a line current regulator 126, a line current monitor 127, an off-hook impedance matcher 128, and a switch circuit 121.
In the embodiment described, the release transistor 15 is also used to regulate line current and for transmitting dialing signals.
The transistor 15 is an NPN transistor having its emitter connected to the common negative terminal C of the diode bridge 11 and having its collector connected to the wire M which serves as the lowest voltage line in the line current regulator circuit 126. The wire M is then connected via a low value resistor 120, a slightly higher value resistor 106 and the emitter-collector junction of an NPN transistor 108 to the low voltage line m. The resistors 120 and 106 may be three and twelve ohms respectively. The base of the release transistor 15 is connected to the common negative terminal C via a resistor 76 and is biased via the emitter-collector junction of a PNP transistor 74.
The base of an NPN transistor 78 receives instructions to turn off the release transistor 15 from an output N of the microprocessor 5. The emitter of the transistor 78 is connected to the low voltage line m and its collector is connected to the unregulated terminal E via a potential divider constituted by resistors 80 and 81 connected in series. The intermediate point of said potential divider is connected to bias the base of a PNP transistor 73 which has its emitter-collector junction connected in parallel with that of a PNP transistor 72. The emitters of these transistors are connected to the unregulated terminal E, while their collectors are connected to the common negative terminal C via a high value resistor 77 which serves to bias a PNP transistor 74 having its emitter-collector junction interconnecting the bases of the transistors 72 and 15.
When a voltage is present at E, and so long as the microprocessor is not applying a positive signal N to the base of the transistor 78, the transistor 15 is turned on by the transistor 74 being turned on. If loop-disconnect dialling is used, or during a timed disconnect pulse, or at the end of a call the microprocessor turns on the transistor 78 thereby turning on the transistor 73 which shorts the emitter-collector junction of the transistor 72 and hence turns off the transistors 74 and 15. For short duration interruptions of the power supply from the line, eg. during dialing, power to the microprocessor 5 is maintained by the capacitor 51, or else by a auxiliary power supply, as is likely to be available if the telephone set is provided with a display screen.
At the end of a call, and after the loop has been opened by the transistor 15, the microprocessor 5 applies a control signal to the line PLE to cause the relay RE to change state, but not until it is safe for its contact re1 to open without risk because the line is no longer passing current.
In this embodiment, the release transistor 15 is also used to regulate the line current. For this purpose, the emitter of the transistor 74 is connected to the collector of an NPN transistor 82 at the output of the line current regulator circuit 126. The emitter of the transistor 82 is connected to the wire M via a resistor 87 of fairly low value, eg. 180 ohms.
The regulator circuit 126 is conventionally designed around an operational amplifer 86 having negative feed-back via a resistor 85 and stabilised by a capacitor 83. The positive input of the amplifier 86 is connected to the wire M via a resistor 91 and the resistor 120, and its negative input is controlled by regulator diode 88 whose voltage is controlled by a potential divider comprising resistors 89 and 90 connected across the terminals of the diode 88 and two resistors 97 and 130 connected in parallel therewith. The mid point of the divider 97, 130 is connected via a resistor 92 to the negative input of the amplifier 86. The resistor 97 has the emitter-collector junction of a PNP transistor 98 connected in parallel. The base of the transistor 98 is connected to the mid point of a potential divider comprising resistors 99 and 100 which is connected in series with the emitter-collector junction of an NPN transistor 101 which is connected to the connection between the resistors 91 and 120. The high voltage end of the parallel potential dividers 97, 130 and 90, 89 is connected to the collector of a PNP transistor 95 whose emitter is cnnected via a resistor 96 to the unregulated positive terminal E.
The base of the transistor 95 is controlled in parallel with the base of the transistor 74 in the circuit 121 via a diode 93, and the transistor 95 serves to supply power to the circuit 126.
The circuit 127 uses a Darlington-connected pair of transistors 116 and 118 in conventional manner as an amplifier to supply power to the circuit 128 from the moment the microprocessor 5 delivers the off-hook signal CGA via the wire CGA, the diode 50 and the wire D. The circuit 127 comprises NPN transistors 111, 114 and 118 and a PNP transistor 116 connected in conventional manner between a wire VA connected to the terminal E of the diode bridge 11 and the wire m in the case of the transistors 111 and 114 and a wire s in the case of the transistors 116 and 118 with suitable bias resistors 110, 112, 113, 115 and 117.
The current supplied to the circuit 128 over the wire s from the transistor 118 is applied to the anode of a zener diode 104 whose cathode is connected to the wire M via the very low value resistor 120. A potential divider comprising resistors 102, 103 is connected across the terminals of the zener diode 104 so that its mid point controls the base of the NPN transistor 101 whose emitter-collector junction connects the case of the transistor 98 to the wire M via the resistors 100 and 120.
The zener diode sets the voltage of the base of an NPN transistor 108 which connects the low voltage wire m to the wire M via the low value resistors 120 and 106. The base of the transistor 108 is thus connected to the anode of the zener diode 104 via a resistor 109 and to the wire M via the resistor 120 and two series connected diodes 105 and 107.
When the transistor 118 is on, it turns on the transistor 108 thereby connecting the circuits connected to the wire m substantially to the common terminal C by virtue of the low values of the resistors 106 and 120. The potential divider 102, 103 serves to keep a constant base current flowing through the transistor 101 of the line current regulator 126 using a floating arrangement.
It will be observed that the line seizing circuit in accordance with the invention enables the line to be seized from any computer controlled device 132 which may be connected to the microprocessor 5, eg. via a two-way link 131, provided that an extra power supply is fitted to keep the microprocessor in operation even when the telephone set 1 is on-hook.
In one embodiment the additional power supply is connected between the terminals G and m and it is supplied with power from the computer device 132 or from a source under its control.
Once the button T has been pressed, or once the relay RE has settled into its stable working position in which the contacts re1 are closed, it is possible to control line seizure by closing the loop whenever required by the device 132, by instructing the microprocessor 5 to switch the transistor 15 from off to on. | Telephone sets associated with terminal units such as modems or telecopiers generally need to be used without the handset being lifted off the gravity switch. Such telephone sets also tend to include electronic circuitry which is powered by DC derived from the telephone line via a diode bridge (11) to protect against reversals of line polarity. The line is initially looped by a user-operated switch (T) having contacts (t1) connected in parallel with the gravity switch looping contacts (cc1), and thus on the line or AC side of the bridge (11). Once adequate power is supplied to a controlling microprocessor (5), it causes a relay (RE) to close line-holding contacts (re1) in parallel with the looping contacts already mentioned (t1, cc1). The loop is released by means of a release transistor (15) connected in a common return wire on the DC side of the bridge (11). The line-holding contacts are not released until current has ceased to flow in the line, thereby enabling a miniature relay to be used without fear of line current surges welding its contacts together. | 7 |
CROSS-REFERENCE TO RELATED APPLICATION
This application is a continuation-in-part of copending U.S. application Ser. No. 399,483 filed July 19, 1982, now abandoned.
BACKGROUND OF THE INVENTION
Conductive plastic compositions have been well received as desirable raw materials for the fabrication of a variety of specialized accessories and components, including static electricity dissipation devices, electrical heating elements, equipment parts for high frequency protection and/or electromagnetic interference (EMI) shielding and a variety of other electrical components such as electrodes, terminals, connectors, and the like.
Thermosetting or heat-curable polymer systems have been most prominent in the majority of such conductive plastics materials which have been developed so far. For certain electrical applications, the resistance of many thermosetting materials to high temperature service conditions is a major consideration. However, a generally more important factor probably resides in the inherent reactivity responsible for their thermosetting character and which tends to increase the polymeric interaction with the finely subdivided conductive solids (e.g., metallic powders, carbon blacks, and the like) that must be incorporated into the polymeric base material in order to provide appropriate levels of electrical conductivity.
Most thermoplastic resins, on the other hand, are considerably less responsive to additions of finely divided solid fillers, often resulting in an actual deterioration of many structurally significant physical properties when filled with carbon blacks, powdered metals, and the like, to the extent required for practical levels of electroconductivity. Such deficiencies have severely limited applications accessed by conductive thermoplastic compositions, confining them for the most part to fabrication of at least partially supported auxiliary elements and secondary components like seals, gaskets, inserts and electrodes.
In spite of such difficulties, filled thermoplastic systems have, of course, continued to receive attention since rigid thermoplastic resins offer definite advantages over most thermosetting materials in regard to ease of handling, melt processing convenience and the simplicity of fabricating finished articles therefrom by the usual high speed plastic forming techniques such as extrusion, injection molding, and the like. Indicative of approaches which have been taken in an effort to develop metal-filled thermoplastic compositions with improved overall performance and utility are those disclosed in the publications summarized below.
U.S. Pat. No. 3,491,056 to Saunders et al discloses the rare ability of finely divided aluminum powder to strengthen a specialty thermoplastic resin derived from the prescribed copolymerization of ethylene with an unsaturated carboxylic acid such as acrylic acid. It appears, however, that outstanding levels of electrical conductivity were not achieved in this system even with a 50% by volume loading of conductive filler unless some of the fine aluminum powder was replaced with carbon black (e.g., 16% by volume as in Example 7).
U.S. Pat. No. 3,867,315 to Tigner et al is much more concerned with achieving good electrical conductivity levels without excessive volume loadings of the particular metallic filler material. This is accomplished by including various ionic metal salts along with the metallic filler, which is either copper or contains accessible copper. A broad list of thermoplastic resins is recited, but experimental data is presented only for a blend of 2 parts polyethylene with 1 part of a 72/28 copolymer of ethylene and vinyl acetate, and no physical strength properties whatsoever are indicated. A closely related patent is U.S. Pat. No. 3,919,122 to Tigner which deals with substantially the same system except that the ionic salt is a metal halide salt which is formed "in situ" from free metal and a suitable halide source. The preferred halide source is a halogen-containing polymer (notably one derived from vinylidene chloride), with a copolymer of vinyl chloride and vinylidene chloride in respective weight proportions of 27:73 being used in most of the illustrative examples. However, the only metallic filler used in said examples is a brass powder with an average particle size of 5 to 12 microns and, again, no physical strength measurements are presented.
U.S. patent application Ser. No. 238,757 filed Feb. 27, 1981, now abandoned, to Kleiner describes a flame retardant thermoplastic filled with anisometrically shaped aluminum particles in amounts of from 12 to about 40% by volume which exhibit good electroconductivity. However, the ability to maintain the electroconductivity while lowering the amount of aluminum particle filler needed to achieve the desired level of electroconductivity through the addition of a hard low aspect ratio filler is not realized.
Another approach to achieving highly conductive metal-filled plastic composites at very low volume loadings of the metallic filler has been resorted to from time to time in this art. The basics of this approach, which is often referred to as the "segregated metal particle network" technique, is the careful observance of several critical processing conditions in fashioning the finished composite. These conditions generally include dry mixing of rather large granules of organic polymer with much smaller particles of metal and compacting the resulting mixture under pressures and temperatures controlled to cause some coalescence or sintering between neighboring polymeric granules without effecting sufficient melt flow to result in extensive intermingling with the fine metallic particles distributed therebetween. By means of such techniques, highly conductive, compacted metal-polymer composites can be obtained at metal filler loadings below about 10% by volume, due to the resulting preferential segregation of metal particles into extended chain-like networks which apparently serve as a system of three-dimensionally interconnected pathways through which current can flow. Patents describing products made by such techniques include U.S. Pat. Nos. 2,761,854 to Coler and 3,708,387 to Turner et al. Additional descriptions are also found in the basic research literature, including such recent journal articles as:
Journal of Applied Polymer Science 20, pp. 25752580 (1976) by Mukhopadhyay et al and Polymer Engineering and Science 19, pp. 533-544 (1979) by Bhattacharyya et al.
Unfortunately, industrial applications for said products appear to be extremely limited since the associated techniques are totally abhorrent to the high speed, "fused state" mixing and molding operations for which thermoplastic materials are so well suited and for which reason they are usually selected in commercial practice. Furthermore, in view of the inherent heterogeneous nature of such "segregated network" metal-polymer compacts, it is very doubtful that adequate manufacturing uniformity and reproducibility could be achieved for commercial articles except possibly those of the simplest shape and design and least demanding fields of application.
In view of the apparent state of this art, a considerable need continues to exist for improved and more versatile metal-filled polymeric compositions. One of the most challenging raw material requirements in this field resides in the need for conductive thermoplastic molding compounds suitable for forming flame retardant structural members of sufficient size, mass and complexity to serve as electronic cabinet housings, dampers and/or shields for absorbing or blocking out electromagnetic field effects or other high frequency electrical emissions. The region of high frequency generally addressed is that region referred to as the radio frequencies, although protection from interference in this region as well as in the microwave frequency region can also be achieved.
Thus, for example, the computer and auto industries have set guidelines which indicate that materials suitable for cabinet housings and having a shielding effectiveness (SE) of 20 to 30 dB will apparently meet 50% of their needs, while an SE of 30 to 40 dB will apparently meet 95% of their needs. Shielding effectiveness is an absolute ratio normally expressed in decibles (dB) and defined on a logarithmic scale through the following equations SE=20 log (Ei/Et) or SE=10 log (Pi/Pt) where E is the field strength in volts per unit length, P is the field strength in watts per unit area, i is the incident field and t is the transmitted field. Alternatively, SE can also be expressed on a linear scale as a percent attenuation (PA). PA is simply (Ei/Et)×(100) or (Pi/Pt)×(100). Thus, 99% attenuation corresponds to 20 dB, 99.9% to 30 dB and 99.99% to 40 dB. Finally, it should be pointed out that there is often a crude correlation between the shielding effectiveness and the volume resistivity, such that a volume resistivity of lower than 6 ohm-cm usually insures that the shielding effectiveness will be at least 20 dB.
It is also understood, however, that this level of shielding effectiveness is not needed for "anti-static" applications and, therefore, lower levels of protection will suffice, for example, volume resistivity levels of less than 1×10 8 ohm-cm or surface resistivities below approximately 10 9 ohm/square.
Accordingly, a goal of the present invention is to provide compounds of high electroconductivity. A more specific objective of this invention is to formulate thermoplastic molding compounds of exceptional levels of electroconductivity, while reducing the total amount of metallic filler needed to achieve the desired electroconductivity characteristics. Such molding compounds are particularly needed for certain specialized structural uses, such as EMI shielding members, electronic equipment housings, and the like, and thus represent a preferred embodiment of the present invention.
SUMMARY OF THE INVENTION
Broadly stated, the present invention relates to a resinous composition particularly adapted for preparing electroconductive molded or extruded articles having reduced loadings of finely divided conductive filler, said composition comprising: between about 0.1% and about 40% by volume of said conductive filler in conjunction with from above 0.1 phr to about 15 prh by weight, based on the composition resin, of a finely divided, hard low aspect ratio filler substantially uniformly dispersed within a cementitious, at least predominantly resinous, matrix.
In other aspects, the present invention relates to processes for producing resinous, electroconductive compositions as well as to premix compositions useful in such processes.
DETAILED DESCRIPTION
Resins serve as the principal component of the molding and/or extrusion compounds of the present invention. It is contemplated that these can be any thermosetting or thermoplastic resin which can be blended with particulate substance while in a plasticated uncured or uncross-linked condition. The thermoplastic resins are preferred for quick fabrication by simple molding techniques. Examples of thermoplastic resins which can be blended with particulate substance are: the AAS resins prepared from acrylonitrile, acrylic rubber and styrene, or blends of same with poly(vinyl chloride) and other thermoplastics; the ABS resins prepared from acrylonitrile, butadiene and styrene; blends of ABS resins with other thermoplastics such as, poly(vinyl chloride), poly (alpha methyl styrene) and poly(methacrylic acid); acrylic resins and modified acrylic resins, e.g., poly (methyl methacrylate) and copolymers of styrene and methyl methacrylate; the cellulosic plastics, such as, cellulose acetate, cellulose acetate butyrate, cellulose propionate, ethyl cellulose, cellulose nitrate and mixtures such as of ethyl cellulose plastics; chlorinated polyether; the fluoroplastics, e.g., polytetrafluoro- ethylene, poly (vinylidene fluoride), the fluorinated ethylene-propylene and the chlorotrifluoroethylene plastics; the phenoxy resins; the polyamide resins; the polybutadiene-type resins including butadiene-styrene copolymer and polybutadiene; the polycarbonates; the polyethylene resins, such as, high and low-density polyethylene; copolymers of polyethylene with other materials; chlorinated polyethylenes; chlorosulfonated polyethylenes; ethylene vinyl acetate copolymer; poly (2,6-dimethyl-1, 4-phenylene oxide) based blends; the polypropylenes; the polysulfones; the polyester resins such as poly(butylene terephthalate) resin; the polystyrenes; styrene copolymers; and vinyl polymers and copolymers, such as, poly (vinyl chloride), chlorinated poly (vinyl chloride), and copolymers such as vinyl chloride with vinyl acetate, vinyl chloride with vinyl acetate plus vinyl alcohol and vinyl chloride with vinylidene chloride.
The electroconductive filler materials which are suitable for use in the present invention include metal particles, metalized nonconductive substrate particles, and mixtures thereof. In the case of metal particles, the particles are generally extremely finely divided. Moreover, they typically have a strongly anisometric shape and at least one aspect ratio of over about 10/1. On the other hand, they may have an aspect ratio on the order of 200:1 or 300:1 or more, and with the smallest characteristic linear dimension, which can be thickness or diameter, having a mean value of at least about 0.1 micron, but not over about 100 microns. It is to be understood that metal fibers, metalized nonconductive substrate fibers, mixtures thereof and mixtures with other suitable particulates, e.g., metal powders and flakes, are also suitable electroconductive fillers for use in the present invention. In the case of fibers the smallest characteristic linear dimension is the fiber diameter. Moreover during subsequent processing, such as in blending with other composition components, the aspect ratio can be reduced, e.g., as by a crushing action, such that the aspect ratio for the particles is to be understood as for particles before such processing. Examples of suitable metal particles include, for example, flakes and/or fibers of aluminum, copper, iron, steel such as stainless steel, magnesium, chromium, tin, nickel, zinc, titanium, bronze and alloys and mixtures thereof. Suitable metalized nonconductive substrates include glass beads and/or fibers coated with any of the above, mentioned metals, alloys and mixtures. In addition, mixtures and combinations of the above are possible and in some cases may be advantageous. The electroconductive filler may be present in the composition in an amount up to about 40 volume percent or more, or in an amount of as little as about 0.1 volume percent. More typically such amount for this filler will be within the range from on the order of about 0.2 to 0.3 volume percent up to about 30 volume percent. In general, the lower loading are for fibrous fillers. The invention is of particular interest for compositions containing modest amounts of electroconductive fibers, such as from about 0.2 volume percent, and more generally from about 0.5 volume percent, up to a maximum of about 5 volume percent of such fibers. For such compositions it is not unusual for the amount of the hard filler, by weight, to exceed the weight amount of the conductive filler.
The hard filler material which works synergistically with the finely divided electroconductive filler is used in amounts of from above 0.1 phr (parts per hundred, resin), and more usually from above about 0.2 phr to about 15 phr (parts per hundred, resin), by weight, based on the weight of the cementitious matrix resin. An amount of 0.1 phr can be insufficient for providing enhanced reduction in resistivity. Usually, for economy, the hard filler is present in an amount below about 10 phr. Generally, these fillers are any pigments or coloring oxides or inorganic (multi-valent) metallic salts of the requisite hardness. Such fillers as are most suitable can include individual non-conductive hard low aspect ratio fillers, e.g., TiO 2 , mixtures of hard low aspect ratio fillers, e.g., TiO 2 mixed with Fe 2 O 3 , and mixed metal hard low aspect ratio fillers e.g., BaTiO 2 . The latter and related materials are referred to herein as "mixed metals oxides," whereas the TiO 2 and Fe 2 O 3 is referred to as a "mixture of metal oxides." The most suitable hard fillers have a Moh hardness number within the range of from above about 4 up to about 10. Useful materials should have a Moh hardness greater than about 3.5, while those within the range of greater than 3.5 up to about 4 are useful especially in mixture with harder fillers.
Low aspect ratio for the hard fillers is meant to convey a ratio of long dimension, or length to short dimension, e.g., thickness (or diameter) of less than about 10:1. Such may often be on the order of about 3 or less, while approaching one for particles of more spherical shape. Moreover, such fillers can have mean minimum characteristic linear dimension, i.e., thickness or diameter, of at least about 0.1 micron and not above about 25 microns. For the more chunky-bodied or block-like fillers, including those of the nature of spheres, it is important that they have mean primary particle diameters of less than 25 microns, and preferably less than about 15 microns, for the most enhanced dispersion of the hard filler in the resin matrix. It is important the this hard filler be very evenly and uniformly dispersed within the cementitious matrix before use. This is discussed more particularly hereinbelow as well as by way of the exemplary teachings. Examples of the suitable hard filler materials include, for example, metal oxides such as from cobalt, aluminum, chromium, iron, zinc, titanium, manganese, antimony, nickel and copper, as well as mixtures of such metal oxides and of mixed metal oxides of the foregoing where such exist. Other suitable hard fillers include silicon oxides, metal carbides, silicon carbide, particulate glass including glass beads, and mixtures of the foregoing. Compounded particles, e.g., compounded metal oxide particles such as disclosed in U.S. Pat. No. 4,373,013, are also contemplated for use. Presently preferred for efficiency and economy are titanium dioxide and mixed metal oxides, e.g., those derived from manganese, antimony, titanium, aluminum, chromium, cobalt and iron. Although the foregoing nonconductive materials are most suitable, it is also known that certain hard, conductive metal particles such as those from the metals of Group VIII, including nickel and nickel/iron alloys can be useful as the hard filler so long as they are in low aspect ratio form. There is, however, the caveat in this situation that said metal particles not also serve as the conductive filler. Regardless of being conductive or nonconductive in the field of use, it is preferred for most efficient dispersion of the hard fillers during processing that they maintain particulate integrity throughout, e.g., in blending and molding and/or extrusion operations. Such fillers are thus preferably inert, and by this is meant that although they may be subjected to some crushing operation in processing, or be electroconductive in finished articles, they nevertheless maintain their particulate nature during processing operations.
In addition to the use of the finely divided electroconductive fillers, hard fillers and the base resins, it may be desirable to include in the cementitious matrix, additional ingredients including lubricants and stabilizers. Lubricants can include solid waxy lubricants such as derived from paraffinic hydrocarbon fractions found in mineral deposits such as petroleum, peat and coal or from essentially aliphatic hydrocarbon polymers such as polyethylene and similar polyolefins, including such materials which have been partially oxidized, animal and plant products such as wool wax and castor wax, as well as various mixtures of any of the same. Examples of waxy lubricants are oxidized polyethylene, ester waxes, polyethylene waxes and amide waxes. Also there may be used fatty acid salts (soaps) such as of magnesium, lithium and/or alkaline earth metals like calcium, strontium and barium. Representative stabilizing compounds can be of Group IVA or VA metals. These stabilizing compounds may be primarily those containing tin, lead or antimony and include their soaps, for example, stearates or octoates and other organic salts, for example, phenolates or maleates. Many different inorganic and/or organic salts of lead, for example, such as sulfates, silicates, phosphites, and phthalates.
Regarding additional ingredients, and after the most important from the point of being advantageous in relatively large amounts, are the polymeric modifiers. Frequently, impact modifiers are the hybrid elastomeric/plastomeric copolymer products formed by graft-type polymerization of one or more suitable monomers from families such as the vinyl aromatics, acrylate monomers and acrylonitriles with a preformed rubbery backbone or elastomeric trunk polymer, particularly the well-known butadiene-containing rubbers. Other nongrafted polymeric impact modifiers are also known, such as, for example, ethylene-vinyl acetate copolymers and chlorinated polyethylenes, and these sometimes can be used in appropriate amounts herein, either alone or together or in combinations with graft copolymers.
Other polymeric modifiers of interest are generally wholly rigid thermoplastic resins, often referred to as "processing aids." These may be added to improve melt flow and/or processability of molding compositions and/or to improve high temperature properties, and include post-chlorinated vinyl chloride resins as well as a wide variety of low to high molecular weight miscible copolymers. Examples of such copolymers are, for example, those of methyl methacrylate with ethyl acrylate and/or of acrylonitrile with styrene and/or alpha-methyl styrene.
Further optional ingredients such as pigments, opacifiers, colorants, u.v. stabilizers, liquid lubricants or plasticizers, syngerists or supplemental stabilizers, inert fillers and the like may also be useful. Inert fillers can include fibrous, reinforcing materials such as fiber glass, graphite and silicon carbide fibers. The total amount of liquid components should be monitored and limited to levels which do not seriously impair either electroconductivity levels or the overall balance of desirable physical properties. For example, to avoid problems of this nature, the total amount of liquid components for use with vinyl resins should not typically exceed about 5% by weight of the total thermoplastic cementitious matrix. Liquid components are those components, as described above, which are liquid at ambient temperatures at normal pressures. It is thus to be understood that the resinous matrix may in some instances be merely resin alone, although such is not preferred so that it will most always include some of the foregoing additional ingredients.
In the present invention where the preparation of thermoplastic molding and extrusion compositions is called for, this can generally be accomplished by adaptively coordinated use of known types of mixing equipment to combine the various components thereof into a homogeneously blended mixture consisting of a fused, resin-based cementitious matrix through which the finely divided electroconductive particles and the finely divided hard filler material are well-dispersed with minimal damage thereto. Once achieved, this homogeneously blended dispersion of electroconductive particles and said hard filler through a continuous, fused mass of said cementitious matrix can be readily converted to compact pellets or granules by the usual plastic compounding techniques such as extrusion pelletizing, chopping, dicing, etc.
To prevent extensive pulverizing or breaking up of said electroconductive particles during their incorporation and dispersion through said matrix, any dry blending operations for combining them with the matrix component should entail relatively mild or low speed agitation systems. It is preferable with the thermoplastic resins, but not critical, to have the particles ultimate thorough incorporation and dispersion through the resin matrix effected by a melt shearing and masticating step during which the resinous components reach a fused state and which is normally near the end of the overall mixing sequence. The characteristic slow speed kneading action of such a step enables said electroconductive particles to be dispersed thoroughly into a softened, viscous, plasticated matrix without extensive damage of their structural integrity. A variety of plasticating and melt shearing equipment is available for such use, including essentially batch type mixing equipment such as Banbury and roll mills as well as essentially continuous mixers such as kneaders and mixing extruders represented by both twin screw devices and certain one and two stage, single screw devices.
Certain of the minor auxiliary components of the present compositions can be introduced at almost any step of the overall mixing sequence. By the same token, certain other minor additives might logically be introduced along with such fillers, such as wetting agents, dispersion aids and/or other processing aids.
However, in the interest of overall production efficiency and economy, it is generally desirable to premix matrix components. Thus, the resin and the hard filler, whether the resin be in pellet or powder form, can be premixed to form a homogeneous blend, before subjecting same to a melt shearing and plasticating step. In such operation, it is preferred to employ downstream addition of electroconductive particles during such plasticating step. Normally, liquid components and at least a major portion of the more significant polymeric modifiers are also generally included in such powder blend premixes. It can also be advantageous for accomplishing uniform dispersion of ingredients to preblend powdered materials in to an admix prior to combination of the admix with the matrix resin. Such powdered admix compositions can include the hard filler along with other very finely divided materials, e.g., impact modifiers, flame retardants and heat distortion temperature modifiers. A minor amount of powdered matrix resin may also be included in such admix.
A wide variety of blending devices known in the art are satisfactory for preparing the powdered admixes or the powder blend premixes from a combination of ingredients. Most efficient of such blenders are the high intensity, rotating blade types, including such commercially available makes as the Henschel Mixer, the Papenmeier Dry Mixer and the Welex Mixers. Due to the high intensity centrifugal action and turbulence created by their rotating blades, these mixers can rapidly create a homogenous powder blend of various particulate ingredients placed therein. A considerable amount of the kinetic energy of such mixers is simultaneously transferred to the ingredient materials as heat through the impacting and shearing performed thereon as well as resultant collisions and impingements within the particulate materials. Such frictional heating may be beneficial, e.g., by softening or melting additional ingredients and assisting in the assimilation of the other ingredients.
Such powdered admixes or the premixes as may contain particulate resin can also be made by less intensive or lower speed powder blending techniques and equipment provided that minimizing the cycle time is not a paramount concern. Such a method is, for example, the mixing of ingredients using a Hobart mixer or a ribbon blender. Supplemental heat, if needed, can be introduced in such cases from an external source, for example, and/or by preheating of the component ingredients, if desirable, for expediting the attainment of a sufficiently homogeneous powder blend.
In order to provide a more complete understanding of the present invention and certain details involved in practicing the same, the following specific examples are provided for illustrative purposes only and without any implication that the specific details disclosed are intended to represent limiting conditions therefor. In said examples, parts and percentages are by weight unless otherwise indicated.
EXAMPLE 1
This example shows how the premix powder blend of matrix components can be produced.
This premix powder blend of matrix components, is used for examples 1 through 6. It contained a rigid PVC suspension type homopolymer with a K value of about 51 as the base resin prepared in accordance with the following formulation. Unless otherwise noted all proportions of each ingredient used are given in parts per 100 parts, by weight, of said PVC.
______________________________________Ingredient Weight Proportion Used______________________________________Tribasic Lead Sulfate 5.0Lead Stearate 1.0MBS Graft Copolymer.sup.(1) 20.8Wax.sup.(2) 5.0Paraffinic Wax.sup.(3) 1.0Rigid thermoplastic 7.0Blending Resin.sup.(4)PE Wax.sup.(5) 0.5Calcium Stearate 1.5______________________________________ .sup.(1) A methyl methacrylatestyrene graft copolymer of a high diene content rubber, supplied by Rohm & Haas under the Trade Name ACRYLOID KM611. .sup.(2) Hydrogenated Castor Oil Base Wax supplied by Associated Lead Inc., under the Trade Name PLASTIFLOW CW2. .sup.(3) Wax 1014 supplied by Boler Petroleum Co. .sup.(4) A linear copolymer of acrylonitrile with a major proportion of vinyl aromatic comonomers (predominately alphamethyl styrene), supplied b Borg Warner under the Trade Name BLENDEX 586. .sup.(5) Wax PA190 supplied by Hoechst.
The blending of said components was accomplished in a high intensity Papenmeier Mixer in the following manner. The lead containing stabilizer compounds were added to the PVC base resin at ambient temperature and mixed for a few minutes until the temperature reached about 49° C. The MBS graft copolymer, combination blend was and the paraffinic wax were charged next, as mixing continues, until the temperature reached about 71° C. At his point the blending resin was charged during continuation of the mixing until the temperature reached 82° C. Finally, the PE wax and calcium stearate were charged and high speed mixing was continued for a few more minutes until the frictional heat generated had raised the temperature of the blended matrix components to about 99° C. The contents were then discharged and cooled, yielding a free flowing, homogeneous powder, hereinafter referred to as the "Matrix Premix".
In the Examples 1 through 6 where samples also contain fillers, e.g., "hard, low aspect ratio fillers", these fillers are introduced into the "Matrix Premix" at the same time as the PE wax and calcium stearate are introduced. In those cases where the Matrix Premixes contain such added fillers, the particular filler and the amount used are described hereinbelow.
EXAMPLE 2
This example describes how to incorporate particles of aluminum flake at various volume loadings in Matrix Premixes using commercial equipment. As shown in the table below, various Matrix Premixes were used, their differences being in the fillers in the Premix, but with the controls being free from such fillers.
The Matrix Premix and the flake of aluminum having a high aspect ratio of typically 40 to 50 were fed from reservoirs via weigh belt feeders to a starve fed hopper. The starve fed hopper in turn introduced the preweighed components into the entry end of a dual rotor counter-rotating No. 4 Farrel Continuous Mixer (with #7 rotors at 210 rpm). The TEFLON orifice utilized an discharge opening size of approximately 1.3 inches. The discharge temperature of the mixed material ranged from about 165° C. to about 181° C. The hopper and body of the mixer were run without external heating and the rotors were heated to about 93° C. This material was then fed directly into the entry end of a six inch hot feed extruder with a dry die face pelletizer and the pelletized material was cooled via a fluidized bed system. This extruder had a 11/4" flight screw for feeding and utilized a compression ratio of 1.5:1.
This resulted in a pelletized flame retardant, thermoplastic composition for use in further processing, such as an injection molding machine.
Table A describes the composition of eighteen pelletized samples prepared as described above as well as some properties of the hard low aspect ratio fillers used. Included are control examples having no hard low aspect ratio fillers (samples 2A-2D) and comparison examples that have soft low aspect ratio fillers (samples 2I-2M), or high aspect ratio fillers (samples 2P and 2Q), or have an unusually great mean primary particle diameter (sample 2N). The structural, particulate nickel of sample 2P is recognized for its tendency to readily form agglomerate particles, and is therefore judged to be unsuitable for the present invention owing to its high, effective aspect ratio.
TABLE A__________________________________________________________________________ FILLER PROPERTIES Mean Aluminum Primary Typical Flake Amount Particle Shape and Hardness ResistivitySample No. (wt. %) Filler (phr) dia. (u) (aspect ratio) (Moh) (ohm-cm)__________________________________________________________________________2 A* 0 -- -- -- -- -- --(control)2 B 35 -- -- -- -- -- --(control)2 C 30 -- -- -- -- -- --(control)2 D 25 -- -- -- -- -- --(control)2 E 25 TiO.sub.2.sup.(1) 2 0.18 Spherical 6-6.5 10.sup.13 -10.sup.18 (low)**2 F 30 TiO.sub.2.sup.(1) 2 0.18 Spherical 6-6.5 10.sup.13 -10.sup.18 (low)**2 G 30 TiO.sub.2.sup.(1) 2 0.18 Spherical 6-6.5 10.sup.13 -10.sup.18 (low)**2 H 30 TiO.sub.2.sup.(2) 2 0.03 -- 6-6.5 10.sup.13 -10.sup.182 I 30 CaCO.sub.3.sup.(3) 2 0.07 Block-Like 2.5-3 insulator(comparison) (low)**2 J 30 CaCO.sub.3.sup.(4) 2 0.5 Block-Like 2.5-3 insulator(comparison) (low)**2 K 30 CaCO.sub.3.sup.(5) 2 3.7 Block-Like 2.5-3 insulator(comparison) (low)**2 L 30 Talc.sup.(6) 2 2.5 Platelet 1-2 insulator(comparison)2 M 30 BaSO.sub.4.sup.(7) 2 10 Block/Cube 3-3.5 1 × 10.sup.14(comparison) (low)**2 N 30 Glass Spheres.sup.(8) 1.5 25 Spherical 5.5 2 × 10.sup.13(comparison) (low)**2 O 30 Nickel.sup.(9) 4 3-7 Spherical 5-6 conductor Powder (low)**2 P 30 Nickel.sup.(10) 4 2.2-2.8 Structural 5-6 conductor(comparison) Powder2 Q 30 Nickel.sup.(11) 4 1.2 Platelet 5-6 conductor(comparison) Flake Thick (33:1)2 R 30 Mixed Metal.sup.(12) 2 1.3 Spherical 6-7 insulator Oxide (low)**__________________________________________________________________________ *Typical rigid polyvinyl chloride compound typically has a bulk resistivity of 10.sup.16. **Low aspect ratio = less than 3 .sup.(1) A rutile powder supplied by duPont under the trade designation R101. .sup.(2) A powder, ostensibly primarily anatase, supplied by De Gussa under the trade designation P25 .sup.(3) Pfizer precipitated calcium carbon sold under the Trade Name Ultraphlexate .sup.(4) Pfizer precipitated calcium carbonate sold under the Trade Name Superphlex .sup.(5) Pfizer ground calcium carbonate sold under the Trade Name Hiphle .sup.(6) Pfizer talc sold under the Trade Name Platy MP 1250 .sup.(7) Pfizer No. 1 barium sulfate .sup.(8) Potter's Ind. spheres, grade 3,000, silane coated .sup.(9) INCO powdered nickel 123 .sup.(10) INCO nickel 255 .sup.(11) Novamet nickel flake HCA1 .sup.(12) Shepherd's No. 153 pigment, a mixed metal oxide of Mn, Sb and T
EXAMPLE 3
This example shows the high electroconductivity of compositions of the present invention over compositions not containing the "hard filler" materials with sample plaques prepared using commercial injection molding equipment. The sample plaques were made from the corresponding pellets of Example 2 on a 175 ton New Britain Injection Molding Machine. Plaque thickness and bulk resistance are shown below in Table B. Thus, for example, comparative samples 2I-2M containing "soft, low aspect ratio" fillers do not show bulk resistivities as low as samples 2E-2H, containing hard fillers. Also shown is that metal fillers having a low aspect ratio (sample 20) have some synergistic effect but may not be as serviceable as fillers that are not themselves conductive. Sample 2N contains glass spheres lacking in conductivity but having an unusually great mean primary particle diameter. The specific data is set out below in Table B.
TABLE B______________________________________ Aluminum Bulk Thickness Flake Resistance*Sample No. (inches) (wt. %) (ohm-cm)______________________________________2 A Control 0 10.sup.16 **2 B Control 0.123 35 0.0732 C Control 0.121 30 0.0932 D Control 0.120 25 0.1142 E 0.121 25 0.0492 F 0.121 30 0.0472 G 0.121 30 0.0462 H 0.121 30 0.0552 I Comparison 0.121 30 0.1792 J Comparison 0.121 30 0.2042 K Comparison 0.121 30 0.1512 L Comparison 0.122 30 0.7072 M Comparison 0.120 30 0.1332 N Comparison 0.121 30 0.1252 O 0.122 30 0.0682 P Comparison 0.122 30 0.1352 Q Comparison 0.121 30 0.1502 R 0.120 30 0.034______________________________________ *Resistance was measured using clamps having pins that penetrated the sample surface. These clamps had 5" of sample between them through which the resistance was measured. The current used was 0.25 amp and the clamping pressure on the samples was 30 ft. lb. torque in all cases. **Typical
EXAMPLE 4
This example shows how small additions of hard, low aspect ratio filler allows for the useful amount of conductive filler, in this case aluminum flake, to be lowered greatly while retaining excellent electromagnetic interference (EMI) shielding as evidenced by low bulk resistivities. The samples in Table C below are all made from the "Matrix Premix" of Example 1. The aluminum flake was introduced as in Example 2 and injection molded plaques were made using the 175T New Britain injection molding machine as in Example 3. The notched izod, flexural strength and flexural modulus tests were all conducted according to ASTM standards. The resistivity measurements were made in accordance with the procedure mentioned in Example 3. Samples 4A, 4B and 4C are control samples containing no hard, low aspect ratio filler. Sample 4D is comparative, as the 0.1 phr amount of the filler is insufficient for enhancing sample resistivity.
TABLE C__________________________________________________________________________ Notched Flexural Flexural Al Flake TiO.sub.2 Resistivity Izod Strength ModulusSample No. (wt. %) (phr) (ohm-cm) (ft.lb.) (psi) (× 10.sup.3 psi)__________________________________________________________________________4 A Control 40 0 0.108 2.45 6918 4394 B Control 34 0 0.134 3.00 7967 4674 C Control 29 0 0.109 3.33 7797 4774 D Comparative 27 0.1 0.137 4.54 8920 4464 E 27 4 0.023 3.93 8373 4544 F 29 4 0.009 3.30 7308 4354 G 26 6 0.005 3.16 7003 484__________________________________________________________________________
EXAMPLE 5
This example, in conjunction with Example 6, describes how to incorporate aluminum fibers at various loadings of hard fillers in the Matrix Premix formulation of Example 1 using a laboratory two roll mill. First the matrix components of Example 1, plus the aluminum fibers, were tumbled together. The aluminum fibers had a high aspect ratio of 320. The resulting blend was then milled as more particularly described in Example 6 herein below. Table D describes the composition of five samples as well as some properties of the hard low aspect ratio fillers used. Sample 5A is a control example which contains no hard low aspect ratio filler.
TABLE D__________________________________________________________________________ FILLER PROPERTIES Mean Aluminum Filler Primary Typical Fiber* Amount Particle Shape and Hardness ResistivitySample No. (wt. %) Filler (phr) dia. (u) (aspect ratio) (Moh) (ohm-cm)__________________________________________________________________________5 A Control 40 None 10.sup.165 B 40 Mixed Metal.sup.(1) 3 1.3 Spherical 6-7 Insulator Oxide (low)**5 C 40 TiO.sub.2.sup.(2) 3 0.18 Spherical 6-6.5 10.sup.13 -10.sup.18 (low)**5 D 40 Mixed Metal.sup.(1) 6 1.3 Spherical 6-7 Insulator Oxide (low)**5 E 40 TiO.sub.2.sup.(2) 6 0.18 Spherical 6-6.5 10.sup.13 -10.sup.18 (low)**__________________________________________________________________________ *The aluminum fiber used had a mean diameter of 20 microns and a mean length of 1/4". **Low aspect ratio = less than 3. .sup.(1) A mixed metal oxide of Mn, Sb and Ti supplied under the trade designation Shepherd's No. 8. .sup.(2) A rutile powder supplied by duPont under the trade designation R101.
EXAMPLE 6
This example shows the high electroconductivity of the compositions from Example 5, using the metal fiber conductive filler and hard low aspect ratio fillers, but compared against the same composition without said hard low aspect ratio filler. The Example 5 compositions were milled on a two roll mill at 330°-340° F. for five minutes, then the resulting milled sheet was cooled to room temperature and cut. The cut portions were compression molded using a steam heated press at 330°-340° F. The specific data for the molded samples is set out below in Table E.
TABLE E______________________________________ Thickness Aluminum Fiber Bulk Resistance*Sample No. (inches) (wt. %) (ohm-cm)______________________________________5 A Control 0.119 40 2.7525 B 0.118 40 1.3865 C 0.118 40 1.2365 D 0.120 40 0.7905 E 0.119 40 1.397______________________________________ *Resistance was measured in the same manner as described in Example 3.
This example demonstrates the serviceability of the invention in compression molding operation, although as noted hereinbefore, more dramatic, consistent results can be expected in other operations such as injection molding and extrusion processes.
EXAMPLE 7
The titanium dioxide described in Example 5 plus an injection molding grade of polypropylene pellets supplied by Hercules Incorporated under the trade designation Profax 6523 are blended together and then introduced to a model Buss MDK-46 kneader manufactured by Buss-Condux Incorporated. By downstream addition to the resulting plasticated mixture in the kneader, before the mixture reaches a cross head extruder, aluminum particles of principally thin flake form are introduced. More particularly the finely divided aluminum had generally tabular structure and was fairly uniform in characteristic linear dimensions, having an average thickness of about 25 microns and lengths and widths averaging about 1250 and 1000 microns respectively, such that the flake aspect ratio approximated about 50:1. The resulting flake-containing, kneaded material passed first through a cross head extruder and then a die face pelletizer. This resulted in a pelletized thermoplastic molding composition for further use, e.g., as in injection molding equipment. In Table F hereinbelow there is noted the volume percent of particulate aluminum in each pelletized sample prepared as well as the titanium dioxide amount (phr), there being no TiO 2 used for the control sample.
Test sample plaques were then prepared from the corresponding pellets by injection molding through a 50 ton injection molder manufactured by Newbury Industries. Resulting test plaques were tested for bulk resistivities with bulk resistance being measured in the same manner as described in Example 3. Results are shown in Table F hereinbelow.
TABLE F______________________________________ Aluminum Filler Bulk Flake Amount ResistanceSample (Volume %) (phr) (ohm-cm)______________________________________Control 25 0 2.00Invention 17 5 0.77______________________________________
EXAMPLE 8
The titanium dioxide of Example 5 plus pellets of acrylonitrile-butadiene-styrene (ABS) compound supplied by Borg Warner Corp. under the trade designation Cycolac KJW were blended together in the manner described in Example 7. There was also blended together with the samples the aluminum flakes of Example 7 in the manner of Example 7 thereby producing a pelletized thermoplastic molding composition. The TiO 2 was not used in one sample for control purposes.
In Table G hereinbelow there is noted the volume percent of particulate aluminum in each pelletized sample prepared as well as the amount for the titanium dioxide (phr).
Test samples were then prepared from the corresponding pellets by injection molding in the manner described in Example 7. Resulting test plaques were tested in the manner described in Example 3 for bulk resistivities. Results are shown in Table G hereinbelow.
TABLE G______________________________________ Aluminum Filler Bulk Flake Amount ResistanceSample (Volume %) (phr) (ohm-cm)______________________________________Control 23 0 6Invention 23 5 0.3______________________________________
EXAMPLE 9
The titanium dioxide of Example 5 plus pellets of polyamide resins, more particularly a Nylon 6 supplied by duPont and a Nylon 11 supplied by Rilsan Incorporated were blended together in the manner described in Example 7. The titanium dioxide was omitted from the Nylon 6 sample for control purposes. The aluminum flake of Example 7 was also used, and the blending was in the manner of Example 7 to thereby produce pelletized material. In Table H hereinbelow there is noted the volume percent of particulate aluminum in each pelletized sample prepared as well as the amount for the titanium dioxide (phr).
Test samples were then prepared from the corresponding pellets by injection molding in the manner described in Example 7. Resulting test plaques were tested in the manner of Example 3 for bulk resistivities. Results are shown in Table H hereinbelow.
TABLE H______________________________________ Aluminum Filler Bulk Flake Amount ResistanceSample (Volume %) (phr) (ohm-cm)______________________________________Control 26 0 2.7-6.9Invention 18.5 5 0.2-0.3______________________________________
EXAMPLE 10
The titanium dioxide of Example 5 plus dried pellets of a flame-retardant, injection molding grade of poly(butyleneterephthalate) resin (PBT) supplied by General Electric Corporation under the trade designation Valox 310 SEO, as well as powdered acrylic resin impact modifier supplied by Rohm and Haas under the trade designation KM 330 were preblended together in a low intensity batch mixer. The titanium dioxide was omitted from one sample for control purposes. Thereafter the blend was kneaded together in the manner of Example 7, with the aluminum flake of Example 7 being added downstream in the kneader, to thereby produce pelletized material. In Table I hereinbelow there is noted the volume percent of particulate aluminum in each pelletized sample prepared as well as the amount for the titanium dioxide (phr). In the control, the weight ratio of the acrylic resin to the PBT was 6:61 and for the invention sample was 5.75:60.
Test sample plaques were then prepared from the corresponding pellets by injection molding in a 175 ton New Britain injection molder. Resulting test plaques were tested as discussed in Example 3 for bulk resistivities. Results are shown in Table I hereinbelow.
TABLE I______________________________________ Aluminum Filler Bulk Flake Amount ResistanceSample (Volume %) (phr) (ohm-cm)______________________________________Control 18.5 0 0.03-0.05Invention 22 1.33 0.006-0.007______________________________________
EXAMPLE 11
The titanium dioxide powder of Example 5, or a mixed metal oxide in its place, plus pellets of flame-retardant, injection molding grade ABS compound supplied by Borg Warner under the trade designation Cycolac KJB were melt blended in a 11/2-inch compounding extruder. The titanium dioxide and mixed metal oxide were omitted from one sample for control purposes. The mixed metal oxide used was either a blue oxide of chromium, cobalt and aluminum supplied under the trade designation Shepherd's No. 190, or a brown oxide of iron and titanium supplied under the trade designation Shepherd's No. 8. For both the control and invention samples there was blended, with the foregoing ingredients, sized stainless steel fibers (type 316L stainless steel) having a mean minimum characteristic linear dimension (diameter) of 8 microns. The melt blended material next passed through a strand die, was subsequently water cooled and then pelletized.
In Table J hereinbelow there is noted the volume percent of stainless steel fiber in each pelletized sample prepared as well as the filler amount (phr) and type used. Test samples were then prepared from the corresponding pellets by injection molding in the manner described in Example 7. Resulting test plaques were tested in the manner described in Example 3 for bulk resistivities. Results are shown in Table J hereinbelow.
TABLE J______________________________________ Stainless Filler Bulk Steel Fiber Amount ResistanceSample (Volume %) Filler (phr) (ohm-cm)______________________________________Control 1.3 None 0 1.8-2.4Invention 1.3 TiO.sub.2 3 0.53-0.56Invention 1.3 Blue Mixed 3 0.85-0.92 Metal OxideInvention 1.3 Brown Mixed 3 0.77-0.92 Metal Oxide______________________________________
EXAMPLE 12
The control for this example was prepared from the PBT resin pellets plus acrylic resin powder impact modifier, both described in Example 10, together with the aluminum flake of Example 7. The weight ratio for acrylic resin powder to PBT resin pellets in the control sample was 6:61. For the invention sample there was used the titanium dioxide powder of Example 5, in a weight ratio to the acrylic resin powder of 5:23. There was then used ten weight percent of this powder combination with a 90 weight percent balance of PBT resin pellets. To this there was further blended the aluminum flake of Example 7. For both the control and the invention samples, ingredients were melt blended and pellets prepared all in the manner of Example 2.
In Table K hereinbelow there is noted the volume percent of particulate aluminum in each pelletized sample prepared. Also noted in the table is the titanium dioxide amount of the invention sample, as a weight amount, basis total sample weight. Test samples were then prepared from the corresponding pellets by injection molding in the manner described in Example 7. Resulting test plaques were tested in the manner described in Example 3 for bulk resistivities. Results are shown in Table K hereinbelow.
TABLE K______________________________________ Aluminum Filler Bulk Flake Amount ResistanceSample (Volume %) (wt. %) (ohm-cm)______________________________________Control 20.2 0 44.3Invention 19.7 2.2 5.8______________________________________
As noted, bulk resistance improvement is dramatic. It is however of interest to compare these results with those obtained in Example 10, wherein the processing means lead to much less crushing of the electroconductive particles when compared to the operations of this example. | This invention is directed to resinous compositions which are generally metal-filled and which also contain hard filler materials. This combination produces unexpectedly better electrical conductivity than metal-filled material without the hard filler materials. Meanwhile there can be retained the resinous composition's ability to be quickly fabricated by simple molding technique into structurally sound rigid articles which are electrically conductive. | 7 |
RELATED APPLICATIONS
[0001] This Application is a continuation-in-part of Provisional U.S. Patent Application No. 60/576,184, entitled “Audible Content with Training Information” filed on May 31, 2004, and naming Albert Shum, et al. as inventors, which application is incorporated entirely herein by reference.
FIELD OF THE INVENTION
[0002] The invention relates to providing training information with audible content. More particularly, various embodiments of the invention relate to a device that plays back audible content for a user, while periodically providing the user with training information.
BACKGROUND OF THE INVENTION
[0003] To measure their performance in a quantifiable manner, athletes will often measure various performance characteristics corresponding to their activities. For example, a runner may measure a total distance traveled during a run, a total elapsed time required to run a distance, the elapsed time required to run a segment of the distance, and/or the average time required to run equal segments of the distance. Likewise, cyclists, ice skaters, sailors, hikers, swimmers, skiers, and other athletes may desire to measure the total distance traveled, a total elapsed time required to travel a distance, the elapsed time required to run a segment of the distance, and/or the average time required to run equal segments of the distance.
[0004] In addition to (or instead of) measuring temporal and positional information, some athletes will measure their biometric information. For example, during an activity, an athlete may employ a heart-rate monitor to monitor his or her heart rate, a thermostat to measure the athlete's body temperature, a blood pressure monitor to measure the athlete's blood pressure, a volumetric expansion monitor to monitor the expansion of the athlete's lungs while performing an activity, an oxygen content meter to measure the amount of oxygen in the athlete's bloodstream (e.g., by measuring the amount of oxygen in the athlete's exhaled breath), or even more sophisticated biometric monitoring device, such as an ECG (electrocardiogram) monitor. The athlete can then use this biometric information to analyze his or her athletic performance.
[0005] Many athletes also prefer to use some type of audible playback device during an athletic activity. For example, many athletes will listen to music or other audible content transmitted over radio waves, decoded from an electronically or magnetically stored file (such as an MP3, AAC or WAV files), or decoded from a file stored on an optical medium (such as a compact disc (CD)) during an athletic activity. Some athletes find that the audible content distracts the athlete from the monotony of an athletic activity, while other athletes believe that audible content with rhythm can be used to help the athlete maintain a desired pace. Still other athletes alternately or additionally choose to carry a wireless telephone during their activities, in case they need to be contacted with an important message.
[0006] While an athlete may monitor positional, temporal, and/or biometric information during an athletic activity, the athlete will not typically monitor this information continuously. Instead, the athlete will only periodically monitor this information. Accordingly, many athletes use a performance monitoring device in conjunction with an audible content playback device. For example, a runner may listen to an MP3 or WAV file player while wearing a watch wirelessly linked to a pedometer on the runner's foot. In this way, the runner can listen to desired audible content, such as music or a book or magazine article read aloud, while periodically monitoring his or her speed and distance.
[0007] While such use of multiple devices does allow an athlete to both enjoy the playback of audible content and monitor performance data, the use of multiple devices may be inconvenient and awkward for the athlete. For example, if an athlete desires to listen to music, receive calls through a wireless telephone, and check performance information, the athlete must physically carry at least three different pieces of equipments. Further, if an athlete is using an MP3 player and receives a call on a wireless telephone, the athlete must remove the headphones for the MP3 player, and break stride by moving the wireless telephone to the athlete's ear. Likewise, if the athlete desires to view performance data, the athlete typically must break stride to move the monitoring device's user interface (e.g., a display on a watch) to a viewable position. Still further, an athlete may find it difficult to concentrate on understanding the performance data while still listening to the audible content.
SUMMARY OF THE INVENTION
[0008] The invention advantageously allows an athlete, such as a runner, to conveniently listen to audible content and receive performance information. For example, various embodiments of the invention employ a single device to both playback audible content and provide monitored performance information to a user. Some embodiments of the invention even provide the performance information to a user audibly, so that the user does not need to move the monitoring device's user interface (e.g., a display on a watch) to a viewable position. Instead, the user can simply listen to the performance information rather than (or in addition to) the audible content.
[0009] These and other features and aspects of the invention will be apparent upon consideration of the following detailed description of the preferred embodiments.
BRIEF DESCRIPTION OF THE DRAWINGS
[0010] FIG. 1 is a block diagram of components of an audible content playback device according to various embodiments of the invention.
[0011] FIGS. 2A-2D illustrate a process by which an audible content playback device can provide a user with both audible content and performance information according to various embodiments of the invention.
[0012] FIG. 3 illustrates one technique by which an audible content playback device according to various embodiments of the invention can reduce the volume of audible content to audibly provide performance data.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
[0013] FIG. 1 illustrates an audible playback device 101 according to various embodiments of the invention. As seen in this figure, the audible playback device 101 interacts with an athletic performance monitor 103 in order to provide audible content playback and athletic performance information to a user 105 . The audible playback device 101 includes an audible content source module 107 , an athletic performance monitor interface 109 , an athletic performance data storage 111 , an audible content playback module 113 , an athletic performance user interface 115 , and a controller 117 . As will be explained in more detail below, one or more of the components 107 - 117 may be implemented using programmable electronic circuitry (sometimes referred to as “hardware”) together with a set of instructions (sometimes referred to as “software”) for controlling the operation of the programmable electronic circuitry. Alternately or additionally, one or more of the components 107 - 117 may be implemented using non-programmable electronic circuitry, or a combination of the two. For example, the audible content playback module 113 may be implemented using programmable circuitry to deliver electronic signals to a piezoelectric emitter for emitting sounds corresponding to the electronic signals.
[0014] The audible content source module 107 may be any device or system for playing back audible content. For example, with some embodiments of the invention, the audible content source module 107 may be a music player for playing back music or voice information, e.g., electronically stored in a music file (such as an MP3, AAC, or WAV file) or retrieved from an optical storage device. Further, the audible content source module 107 may be a radio receiver for receiving and decoding music or voice information transmitted over radio waves. Still further, the audible content source module 107 may include the components of a wireless telephone, for both transmitting and receiving sound information to and from another transceiver device. Moreover, with the still other embodiments of the invention, the audible content source module 107 may include any combination of music player, radio receiver, or mobile telephone transceiver device.
[0015] The athletic performance monitor interface 109 communicates with the athletic performance monitor 103 . The athletic performance monitor 103 may be any desired type of athletic performance monitor. More particularly, the athletic performance monitor 103 may monitor an athlete's positional information, temporal information, biometric information, or any combination thereof. For example, the athletic performance monitor 103 may include any combination of speedometer or GPS tracking device, chronometer or chronograph, heart rate monitor, blood pressure monitor, lung expansion monitor, oxygen content monitor, or other monitoring device.
[0016] With some embodiments of the invention, the athletic performance monitor 103 may be a remote component from the audible playback device 101 . For example, with some embodiments of the invention, the athletic performance monitor 103 may be a pedometer or GPS device remotely located from the audible playback device 101 . With these embodiments of the invention, the athletic performance monitor 103 may communicate with the athletic performance monitor interface 109 through a wired or wireless connection. The wireless connection may be, for example, over a radio frequency, infrared, visible, or ultrasonic wavelength medium. With still other embodiments of the invention, the athletic performance monitor 103 may be incorporated into the audible playback device 101 . For example, if the athletic performance monitor 103 is a chronograph or chronometer, then the athletic performance monitor 103 may be implemented within the audible playback device 101 . For still other embodiments of the invention, the athletic performance monitor 103 may include both remotely located and internally located performance monitoring devices.
[0017] The athletic performance data storage 111 may be any component for storing athletic performance data provided by the athletic performance monitor 103 . For example, the athletic performance data storage 111 may be a solid state storage device, a magnetic storage device, an optical storage device, a punched storage device, or other type of storage device. The audible content playback module 113 may be any type of device for converting audible content information provided by the audible content source module 107 into audible content that may be heard by the user 105 . The athletic performance user interface 115 then provides the performance data measured by the athletic performance monitor 103 to the user 105 . As will be discussed in more detail, the athletic performance user interface 115 may provide athletic performance data to the user visually, audibly, or as a combination of the two. The control 117 then controls the operation of each of the audible content source module 107 , the athletic performance monitor interface 109 , the athletic performance data storage 111 , the audible content playback module 113 , and the athletic performance user interface 115 . Each of these components may communicate with each other over a data bus 119 .
[0018] The operation of an audible playback device 101 according to various embodiments of the invention will now be described with reference to FIGS. 2A-2D . Referring now to FIG. 2A in step 201 the user first positions the athletic performance monitor 103 . For example, if the athletic performance monitor 103 is a pedometer, the user 105 may position the pedometer on one of the user's feet, so that the pedometer may accurately detect every other step taken by the user. Alternately or additionally, if the athletic performance monitor 103 includes a GPS positioning device, then the user may position an antenna for the GPS positioning device high on the user's body, such as on the user's shoulder or head. As previously mentioned, with some embodiments of the invention, the athletic performance monitor 103 may be incorporated into the audible playback device 101 . With these embodiments, the user may omit step 201 .
[0019] Next, in step 203 , the user activates the athletic performance monitor 103 . Again, if the athletic performance monitor 103 is incorporated into the audible playback device 101 , this process may be as simple as depressing a command button on the audible playback device 101 . For example, if the athletic performance monitor 103 is a chronometer, then the user 105 may initiate the operation of the chronometer simply by depressing the appropriate button on the audible playback device 101 .
[0020] If the athletic performance monitor 103 is remotely located from the audible playback device 101 , then the user 105 may need to initiate a communication channel between the athletic performance monitor 103 and the audible playback device 101 in step 205 . Such a process may include, for example, activating the appropriate command buttons on both the athletic performance monitor 103 and the audible playback device 101 within a preset amount of time, so that the athletic performance monitor 103 recognizes signals from the audible playback device 101 and the audible playback device 101 correspondingly recognizes signals from the athletic performance monitor 103 . This type of channel initialization process is well known, and thus will not be discussed in further detail.
[0021] In step 207 , the athletic performance monitor 103 begins collecting athletic performance data. Then, in step 209 , the user 105 selects the audible content to be played back by the audible content playback module 113 . For example, if the audible content source module 107 is an MP3 player, then the user may actuate the necessary buttons or other controls on the audible playback device 101 to select which stored MP3 files are to be audibly played back to the user 105 through the audible content playback module 113 . Similarly, if the audible content source 107 is a radio, then the user may actuate the necessary buttons or other controls to select the radio frequency channel that will be played back to the user 105 through the audible content playback module 113 . Then, in step 211 , the audible playback device 101 begins playing back the audible content selected in step 209 .
[0022] In step 213 , the athletic performance monitor 103 transmits athletic performance data to the athletic performance monitor interface 109 . With some embodiments of the invention, the athletic performance monitor 103 may periodically transmit athletic performance data to the athletic performance monitor interface 109 . With still other embodiments of the invention, however, the athletic performance monitor 103 may continuously transmit athletic performance data to the athletic performance monitor interface 109 . Still further, with some embodiments of the invention, the athletic performance monitor 103 may additionally or alternately provide athletic performance data to the athletic performance monitor interface 109 upon prompting by the user 105 . Correspondingly, in step 215 , the audible playback device 101 receives the athletic performance data from the athletic performance monitor 103 through the athletic performance monitor interface 109 .
[0023] After receiving the athletic performance data from the athletic performance monitor 103 , the audible playback device 101 determines when the athletic performance data is provided to the user 105 through the athletic performance user interface 115 . For example, with some embodiments of the invention, the audible playback device 101 may periodically provide the user with the received athletic performance data at preset intervals (such as, for example, every five minutes, every mile or one-half mile of travel, etc.). Alternately or additionally, the audible playback device 101 may provide the user 105 with the received athletic performance data when the audible playback device 101 receives the performance data from the athletic performance monitor 103 . Still further, with various embodiments of the invention, the audible playback device 101 may alternately or additionally provide the user 105 with received performance data when the user actively requests the performance data by, for example, actuating a button or other control to receive the performance data.
[0024] When the audible playback device 101 determines that the athletic performance data should be provided to the user 105 , the audible playback device 101 reduces the volume of the audible content playback in step 217 . Next, in step 219 , the audible playback device 101 pauses playback of the audible content. Thus, the audible playback device 101 gradually reduces the volume of the audible content before providing the user 105 with the performance data. It should be appreciated, however, that various embodiments of the invention may instead immediately pause or stop playback of the audible content without previously decreasing its volume.
[0025] Next, in step 221 , the audible playback device 101 provides the user with the received performance data. With some embodiments of the invention, the audible playback device 101 may visibly display the performance data received from the athletic performance monitor 103 . For example, the audible playback device 101 may include a display, such as a liquid crystal display or color transistor display, for displaying the received performance data. With various embodiments of the invention where the performance data is only visually provided to the user, then the audible content playback module 113 , may not reduce or pause playback of the audible content, but may instead continue to playback the audible content without interruption or interference.
[0026] With still other embodiments of the invention, however, the athletic performance user interface 115 may audibly relate the received athletic performance data to the user 105 . For example, the athletic performance user interface 115 may include a voice synthesizer, which synthesizes voice information corresponding to the received performance data. With these embodiments, the audible playback device 101 increases the volume of the audible performance data provided to the user when at the volume of the audible content is reduced or paused, as described above.
[0027] For example, FIG. 3 illustrates the initial volume of the playback of the audible content at 301 . As previously noted, the audible playback device 101 reduces the volume of the audible content at 303 until the audible content is paused (or otherwise reduced to a level where it is only nominally audible to the user 105 ) at 305 . Correspondingly, the audible playback device 101 increases the volume of the audible playback of the performance data at 307 , until the volume of the audible playback of the performance data reaches a volume at 309 that may easily be heard by the user 105 . After the performance data has been audibly played back for the user 105 , the athletic performance user interface 115 decreases the volume of (or, alternately pauses the playback of) the performance data at 311 . The audible content playback module 113 then correspondingly increases the volume of the audible content at 313 (or, alternately, restarts the playback of the audible content), until the audible content returns to its normal level at 315 .
[0028] In this manner, the user may conveniently receive both audible content and audible performance data information while engaging in an athletic activity. More particularly, the user 105 need not switch between separate devices to receive both the audible content and the audibly provided performance data.
CONCLUSION
[0029] There are any number of alternative combinations for the invention, which incorporate one or more elements from the specification, including the description, claims, and drawings, in various combinations or sub combinations. It will be apparent to those skilled in the relevant technology, in light of the present specification, that alternate combinations of aspects of the invention, either alone or in combination with one or more elements or steps defined herein, may be utilized as modifications or alterations of the invention or as part of the invention. It may be intended that the written description of the invention contained herein covers all such modifications and alterations. For instance, in various embodiments, a certain order to various processes has been shown. However, any desirable reordering of the steps of these processes is encompassed by the present invention. Also, where certain units of properties such as size (e.g., in bytes or bits) are used, any other units are also envisioned. | An audible playback device that allows an athlete, such as a runner, to conveniently listen to audible content and receive athletic performance information. A single device may be employed to both playback audible content and provide monitored performance information to a user. The performance information may be provided to a user audibly, so that the user does not need to move the monitoring device's user interface to a viewable position. | 0 |
FIELD
The present invention relates to the field of message electronic signatures requiring cryptographic techniques.
It is notably but not exclusively applied to voting, surveying, tendering electronic services, or to any form of anonymous competition. It is also applied to controlling access to paying services such as transportation services, cinema services, by means of an access ticket, allowing the user to access the service for a limited number of times. As soon as the number of accesses has reached a limiting value, he/she should no longer be able to use his/her ticket. In this type of applications, it not necessary to know the identity of the user. It is sufficient for him/her to be able to prove during an access that he/she has right of access.
BACKGROUND
Electronic signature is a mechanism coming under so-called asymmetrical or public key cryptography. In this mechanism, the signatory has a secret or private key and an associated public key. He/she produces the signature of a message by applying to it a cryptographic algorithm using his/her secret key. The verifier may verify the signature by applying the same cryptographic algorithm using the corresponding public key.
The concept of group signature has also been proposed, which allows each member of a group to produce a signature such that a verifier having an adequate public key may verify that the signature was emitted by a member of the group without being able to determine the identity of the signatory. This concept is for example described in documents:
[1] “A Practical and Provably Secure Coalition-Resistant Group Signature Scheme” of G. Ateniese, J. Camenisch, M. Joye and G. Tsudik, in M. Bellare, Editor, Advance in Cryptology—CRYPTO 2000, Vol. 1880 of LNCS, p. 255-270, Springer-Verlag 2000;
[2] “Efficient Group Signature Scheme for Large Groups”, J. Camenisch, M. Stadler, in B. Kalishi, Editors, Advances in Cryptology—EUROCRYPT 97, Vol. 1294 of LNCS, p. 410-424, Springler-Verlag, 1997.
The general principle at the basis of the group signature concept is to associate with each member of the group, a distinct solution to a common difficult problem, this solution being provided by a qualified certifying authority to each new member of the group upon his/her registration. During his/her registration, the member calculates a signature private key which is specific to him/her and interacts with the certifying authority in order to obtain his/her own solution to this difficult problem. The member and the certifying authority also calculate a member certificate which is strongly related to the private key of the member and possibly to the solution of the problem known to the member. To sign a message on behalf of the group, the member encrypts his/her certificate with the public encryption key of the certifying authority, and proves that he/she knows a group member private key, a solution to the difficult problem and a member certificate associated with plain text included in the encrypted text (evidence of belonging to the group). The basis here is cryptography and more particularly evidence of knowledge in order to obtain the desired properties of the group signatures. Verification of a group signature consists of verifying the evidence of knowledge; opening the signature merely consists of decrypting the certificate.
However, in this group signature concept, a certifying authority may at any moment lift the anonymity of the signatory, i.e., determine the identity of the person of the group who has emitted a signature. Further, this type of signature is said to be “non-linkable”, i.e., it does not allow any determination whether or not two signatures were emitted by the same person without lifting the anonymity of the signature. The group signature concept is therefore not very suitable for electronic voting.
There also exists what are called list electronic signatures allowing the members of a list to produce a signature such that a verifier may recognize that the signature was produced by a member of the list, without being able to determine the identity of the member. According to the list signature concept, which is for example described in Patent Application FR 2 842 680 filed by the applicant, the time is divided into sequences marked by a sequence representative with a predefined validity period. During a sequence, each member of the list is authorized to produce the signatures from which a verifier may determine whether or not two signatures were emitted by the same member of the list, without being able to access the identity of the signatory. Thus, if a member of the list produces two signatures during the same sequence, this may be detected without being able to determine the identity of the signatory.
The list signature is thus well suited for voting or electronic surveying, because each voter may produce a list signature of his/her vote, which guarantees his/her anonymity, while the votes emitted by the same person during a same given election (sequence) may be detected. The list signature is also well suited for access tickets such as transportation tickets or cinema tickets, because the user may produce at each access to which he/she is entitled, a list signature which guarantees his/her anonymity, while the number of signatures already emitted during a given sequence may be determined, so as to authorize him/her to access the service for a certain number of times corresponding to the paid amount. However, certain list signatures are said to be “openable”, i.e. a certifying authority may determine the identity of the signatory from a signature.
More specifically, each member of a list calculates during his/her registration in the list, a private key and obtains from a certifying authority a certificate of member of the list, as well as a solution to a difficult problem. The list signature concept does not allow anonymity to be lifted; it does not include any encryption upon producing a signature. At the beginning of a given sequence, the certifying authority generates a sequence representative exclusively valid for the duration of the sequence. Upon producing a signature, a member of the list provides, as in the group signature, the evidence that he/she knows a private key, a solution to a difficult problem and a certificate of member of the list. He/she also calculates a power of the representative of the sequence for which the exponent is the private key. For a given sequence, it is possible to link two signatures produced by a same member of the list, as the representative of the sequence and the private key are set for this sequence. Therefore, the number of signatures emitted by each of the members of the list during a same sequence may thus be counted.
The major drawback of all these concepts results from the fact that they require significant calculations. Indeed, for each generated signature, it is necessary to produce pieces of evidence of knowledge which apply many modular exponentiations in practice, and are very costly in computing time, notably for generating random numbers: a chip card equipped with a cryptographic processor takes about 1 second per modular exponentiation.
A solution to this problem of computing time cost was proposed for group signatures in Patent Application FR 2 834 403 filed by the applicant. This solution which consists of applying a chip card (cryptographic processor), has the disadvantage of the group signatures, i.e., it is not possible to link the signatures emitted by a given member without lifting the anonymity of the signature.
SUMMARY
The object of the present invention is to suppress these drawbacks. This goal is achieved by providing a method for generating a list signature concerning a message to be signed, comprising steps executed by an electronic hardware support of a member of a list, during which the electronic hardware support generates an electronic signature from the message to be signed, and emits the generated signature. According to the invention, the electronic signature is only generated according to the message to be signed, to a sequence number provided by a certifying authority to the electronic hardware support, to evidence of belonging to the list of members, to data specific to the electronic hardware support, and optionally a key from an authority qualified to lift the anonymity of the generated signature.
According to one embodiment of the invention, the electronic hardware support generates according to the sequence number, a pseudo-random number used for generating the electronic signature, the generated pseudo-random number exclusively varying according to the sequence number and to data specific to the electronic hardware support.
According to one embodiment of the invention, generation of the pseudo-random number is carried out by means of an encryption function using a secret key stored by the electronic hardware support and specific to the latter.
According to one embodiment of the invention, the pseudo-random number generated from the sequence number is emitted with the generated electronic signature.
According to one embodiment of the invention, the evidence of belonging to the list of members consists of knowing a secret key common to the members of the list.
According to one embodiment of the invention, the electronic hardware support encrypts with an encryption algorithm, by means of the key of the authority qualified to lift the anonymity of the generated signature, an identification code stored by the electronic hardware support, identifying the member having the electronic hardware support, in order to obtain an encrypted identifier which is used for generating the electronic signature.
According to one embodiment of the invention, a pseudo-random number generated from the sequence number is used for encrypting the identification member code.
Preferably, the encrypted identifier is emitted with the generated electronic signature.
According to one embodiment of the invention, the electronic hardware support receives the sequence number associated with a signature of the sequence number, on behalf of a certifying authority, verifies the signature of the sequence number and refuses to generate a new signature if the signature associated with the sequence number is not correct.
According to one embodiment of the invention, the electronic hardware support generates a signature if the number of signatures emitted beforehand is less than or equal to a maximum number of authorized signatures.
According to one embodiment of the invention, the maximum number of emitted signatures is reset upon a change of sequence number.
The invention also relates to an electronic voting method comprising a phase for organizing elections, during which an organizing authority proceeds with generating parameters required for a poll, and assigns to scrutineers, keys with which ballots may be decrypted and verified, a phase for assigning a signature right to each of the voters, a voting phase during which the voters sign a ballot, and a counting phase during which the scrutineers verify the ballots, and calculate the result of the poll according to the content of the decrypted and valid ballot papers.
According to the invention, the method applies a list signature method according to the one defined hereinbefore, for signing the ballots, each voter being registered as a member of a list, a sequence number being generated for the poll, the maximum number of authorized signatures being equal to 1.
The invention also relates to electronic hardware support comprising means for applying the method defined hereinbefore.
According to one embodiment of the invention, the electronic hardware support appears as a cryptographic microprocessor card.
DRAWINGS
A preferred embodiment of the invention will be described hereafter, as a non-limiting example, with reference to the appended drawings wherein:
FIG. 1 illustrates a system for applying list signature and electronic voting methods, according to the invention;
FIG. 2 schematically illustrates the functional element of a chip card which may be used for generating list signatures in accordance with the method according to the invention;
FIG. 3 illustrates as a flowchart, a list signature procedure according to the invention, which is non-openable and executable by the chip card illustrated in FIG. 2 ;
FIGS. 4 and 5 illustrate as flowcharts, list signature procedures according to the invention, which are openable and executable by the chip card illustrated in FIG. 2 ;
FIG. 6 illustrates as flowcharts, another alternative of list signature procedures according to the invention, executable by the chip card illustrated in FIG. 2 ;
FIGS. 7-9 illustrate as flowcharts, an application of the list signature method according to the invention to electronic voting.
DETAILED DESCRIPTION
The present invention proposes a list signature method wherein all the authorized persons, i.e., belonging to the list, may produce a signature which is anonymous, and the validity of which may be verified by anybody without having to access the identity of the member of the list who emitted the signature.
Such a method may be applied in the system illustrated in FIG. 1 . This system comprises terminals 2 made available to the users and connected to a digital data transmission network 5 , such as the Internet network. Each terminal is advantageously connected to a device 8 for reading an electronic hardware support such as a chip card 7 . Through the network 5 , the users may connect to a server 6 giving access to information for example stored in a database 4 . This system also comprises a computer 1 of a certifying authority which notably delivers chip cards 7 to the users.
Moreover, the system according to the invention is based on placing a group signature, as for example described in the aforementioned Patent Application FR 2 834 403, but nevertheless using a symmetrical or asymmetrical encryption algorithm.
The certifying authority responsible for the group generates all the keys and parameters required for placing the selected group signature and places all the public elements of these elements in a directory (for example the database 4 ).
In order to belong to the group, each member has received from the certifying authority, a chip card 7 for example having the functional architecture illustrated in FIG. 2 . This architecture comprises:
a microprocessor 11 providing the handling of internal functions and execution of application programs stored in a memory of the card, and which may comprise an optimized cryptographic processor for carrying out cryptographic computations;
memories 12 comprising a read- and write-accessible random access memory 14 , with which the processor 11 may record transient data, for example intermediate results of the cryptographic computations, a read only memory 13 , for example of the reprogrammable type (EEPROM) and allowing long term storage of data after manufacturing of the card, such as customization data and application programs, a read only memory 15 of the ROM type programmed with unchanging data during the manufacturing of the chip card and notably allowing the internal handling program of the chip card and possibly encryption data stored;
a communication interface 16 through which the card exchanges data with a suitable chip card reader 8 , and
an internal bus 17 with which the aforementioned elements may be connected together.
The chip card 7 is preferably made secure for preventing access from the outside to certain data notably stored in the ROM memory 15 . Further, in order to apply the list signature method according to the invention, the memories 12 of the card contain means for producing a group signature by using a signature algorithm, an identifier Id i of the member i, a list signature secret key SK L which is common to all the members of the list, a secret key SK i only known to the chip card and specific to the latter, as well as means for generating a pseudo-random number.
If the generated list signatures need to be able to be opened by an authority qualified to lift the anonymity, a symmetrical or asymmetrical encryption algorithm is used. This algorithm takes as input, the message to be encrypted, and possibly a pseudo-random number, for example the pseudo-random number R i , which is different every time the algorithm is executed, so as to produce different encrypted texts of a same message every time it is executed. On the other hand, if the pseudo-random number is not changed, the encrypted text obtained for a same message is always the same.
The certifying authority further manages successive sequences of predetermined periods, for each one of which it randomly generates a unique REPSEQ sequence number which should be different from all the sequence numbers generated beforehand and common to all the members of the list. This number is further preferably signed by the certifying authority.
The sequence number is for example obtained from a randomly generated element for which the certifying authority computes a condensate by means of a hash function, for example the SHA-1 function, and formats the result for example by applying the OS2IP function of the PKCS#1, v2.1 standard.
To sign a message M on behalf of the list, a member of the list uses the chip card 7 which was handed over to him by the certifying authority, which receives as input the message M to be signed and the REPSEQ sequence number via a terminal 2 and a chip card reader 8 .
The chip card then executes the list signature procedure as illustrated in FIG. 3 . This procedure consisting of generating a pseudo-random number R i depending on the chip card, by means of a random number generation function PRNG, receiving as input the REPSEQ sequence number which is in the process of being validated, this input datum being used as a “seed” for the pseudo-random generation function.
In order that the generated pseudo-random number R i depends on the card, the function is selected so that two different cards of members of the list necessarily produce two different pseudo-random numbers from a same REPSEQ sequence number. Typically, the PRNG function is a generic function for all the chip cards handed over to the members of the list and it also receives as a seed the secret key SK i specific to the chip card 7 .
The list signature procedure executed by the chip card then comprises the execution of a group signature algorithm. This algorithm for example consists of concatenating the message M to be signed with the obtained pseudo-random number R i and of applying a conventional signature function Sign to the obtained value by using the secret key of list signature SK L stored by the chip card. The signature S which is delivered at the output by the chip card comprises the pseudo-random number R i concatenated with the signature value S i provided by the signature function Sign:
The signature algorithm applied by this procedure may be synthesized by the following formula:
R i =PRNG ( SK i ,REPSEQ ) (1)
S i =Sign( SK L ,R i ∥M ) (2)
S=R i ∥S i (3)
∥ representing the concatenation operator.
The PRNG function is for example produced with a conventional encryption function, for example of the AES (Advanced Encryption Standard) type, or else with a modular exponentiation which raises the REPSEQ sequence number to the power of SK i modulo n.
The selected Sign function is for example of the RSA (Rivest, Shamir, and Adleman) type consisting in a transformation of the value R i ∥M, followed by raising the amount obtained to the power of SK L modulo n. The transformation which allows formatting of the value R i ∥M is for example the OS2IP function for converting a string of characters into a positive integer, as provided in the PKCS#1, v2.1 standard.
To check the signature S, it is sufficient to apply to it the group signature verification procedure consisting in the example hereinbefore of raising the signature S i to the power of SK L modulo n, to transform the obtained value in order to convert it into a string of characters (I2OSP function of the PKCS#1 standard) and comparing the obtained transformed value to the signed message M. Of course, the verification of the signature also comprises a verification that the value R i associated with the signature S i corresponds to the value R i associated with the message M in the signature.
In order to check if two signatures generated with the same REPSEQ sequence number were emitted by the same member of the list, it is sufficient to compare the numbers R i associated with the signature of the message S i in the signature S, these numbers being identical for both signatures S emitted by the same chip card for the same sequence number.
It should be noted that as the number R i appears in the signature S i which is generated, it is not necessary to emit it with the latter, except if it is desired that even persons which do not have the list key which allows verification of the signature S i , may link two signatures emitted by the same chip card for a same sequence.
The procedure which has just been described generates a so-called non-openable signature, i.e., it is impossible even for an authority having the required rights to lift the anonymity of the obtained list signature S. If it is desired that the signature be openable, the chip card 7 executes the list signature procedure illustrated in FIG. 4 .
As compared with the procedure described hereinbefore with reference to FIG. 3 , this procedure comprises the application of an encryption function Enc to the element Id i with which the member i of the list having the card may be identified, this element consisting of an identifier or a part of a certificate delivered by a certifying authority which is aware of the link between this certificate part and the actual identity of the member. This encryption uses a public encryption key PK MO which is related to a private decryption key SK MO belonging to the authority qualified to lift the anonymity of a signature emitted by a member of the list. The result of this encryption C i is concatenated with the pseudo-random number R i obtained in the same way as in the non-openable list signature procedure; with this concatenation a value R i ∥C i may be obtained, which is concatenated with the message M before its signature, and possibly with the obtained signature S i .
It should be noted that the encryption of the identifier Id i may be symmetrical or asymmetrical. If this encryption is asymmetrical, the card stores the public key PK MO . If this encryption is symmetrical, the card stores in a secured way a secret key SK MO only known to the authority qualified for lifting the anonymity of the signatures emitted by the members of the list.
The signature algorithm applied by this procedure may thus be synthesized by the following formula:
R i =PRNG ( SK i ,REPSEQ ) (4)
C i =Enc ( PK MO ,Id i ) (5)
S i =Sign( SK L ,R i ∥C i ∥M ) (6)
S=R i ∥C i ∥S i (7)
The PRNG function may also consist in a conventional encryption function, for example of the AES type. The encryption function Enc for example consists in a conventional encryption function, for example of the AES or RSA type receiving as input, the key PK MO and the identifier Id i of the member i of the list and possibly the pseudo-random number R i .
The signature function Sign for example consists of converting the value R i ∥C i ∥M applied at the input, into an integer number, by means of a function such as OS2IP of the PKS#1 v2.1 standard, and of applying to the obtained converted value M′ the function of exponentiation modulo n to the power of SL L :
S i =M′ SK L (mod n ) (8)
This algorithm therefore only comprises a random number calculation and two encryption calculations which may each consist in a simple modular exponentiation.
In order to verify that the signature was emitted by a member of the list, it is sufficient to know the signature function (number n in the example above) and the public key PK L of the list. In the example, it is sufficient to compute the following value:
M″=S i PK L (mod n ) (9)
to convert the value M″ by means of the inverse conversion function I2OSP of the PKS#1 v2.1 standard, and to verify the value obtained with the message M.
In order to determine if two signatures were emitted by the same member of the list, it is sufficient to compare the values of the pseudo-random number R i contained in both signatures. As in the example described earlier with reference to FIG. 3 , it is not necessary to emit the pseudo-random number R i with the signature S, except if it is desired that even persons which do not have the list key allowing verification of the signature S i , may link two signatures emitted by the same chip card for a same sequence.
It should be noted that the persons who do not have the key SK MO cannot lift the anonymity of the signature.
If the certifying authority desires to lift the anonymity of the signature, it is sufficient that it applies the decryption function corresponding to the encryption function Enc to the value C i by using the key SK MO . With this operation, it is possible to obtain an identifier with which it may then search in its directory (database 4 ) in order to again find the identity of the signatory member of the list.
Additional security consists of splitting the certifying authority into two distinct entities. The first authority exclusively has the private key SK L and is not aware of the identifiers Id i of the members of the list: it is the authority of the list which is involved during registration of a new member to the list. The second authority only has the SK MO key as well as all the identifiers of the members of the list: it is the opening authority which is alone qualified to lift the anonymity of a signature.
The second authority may also be divided into several entities only having a respective part of the opening key SK MO in order to be able to only decrypt a part of an identifier Id i and an authority establishing the link between an identifier and the identity of the corresponding person.
An alternative which raises the security level consists of assigning a key SK MO i respective to each identifier Id i and only encrypting the pseudo-random number R i which is used for making the encryption probabilistic. Lifting the anonymity of a signature then consists of testing all the encryption keys SK MO i until an identifier Id i appearing in the directory is obtained.
Thus, if a chip card is corrupted, the hacker only has access to the SK MO i of the card without being able to produce a list signature on behalf of an identifier other than the one contained in the card. A hacker will therefore not be able impersonate another member of the list.
It should be noted that if the authority qualified to lift the anonymity of the signatures is the same as the certifying authority handing over chip cards to members of the list, it is not necessary to emit the identifier C i with the signature S, as the latter appears in the signature associated with the signed message.
FIG. 5 illustrates another openable alternative of the list signature method according to the invention.
The procedure illustrated in this figure differs from the one illustrated by FIG. 4 simply by the fact that the pseudo-random number R i obtained by the PRNG function is used in order to make the encryption function probabilistic, the one applied to the identifier Id i of the member of the list having the chip card 7 , the result C i of this encryption being concatenated with the message M to be signed and with the generated signature S i . The signature provided by the chip card contains the produced signature S i concatenated with the encryption value C i .
The signature algorithm applied by this procedure may thus be synthesized by the following formulae:
R i =PRNG ( SK i ,REPSEQ ) (10)
C i =Enc ( PK MO ,R i ,Id i )
S i =Sign( SK L ,C i ∥M ) (11)
S=C i ∥S i (12)
In this way, the value C i associated with the signature S i remains invariant for a same member of the list and a same sequence number. With it, it is therefore possible to determine if two signatures were emitted by a same member of the list.
To raise the anonymity of the signature, it is sufficient to apply to the value C i the decryption function corresponding to the encryption function Enc, by using the secret key SK MO corresponding to the PK MO key.
As earlier, the encryption function Enc may be symmetrical or asymmetrical. In the first case, a single secret key SK MO is used, which is stored by the chip cards of the members of the list and only known to the authority qualified to open the signatures.
According to another embodiment of the invention, the number of signatures capable of being emitted by the chip card may be set. The chip card then comprises means for emitting an error message during the procedure for emitting a signature when the number of already emitted signatures exceeds a predetermined number.
In one embodiment of the invention, the chip card executes the signature generating procedure 40 illustrated in FIG. 7 . In this procedure, the number of signatures able to be emitted by the card is set. The chip card then comprises means for emitting an error message during the procedure for emitting one signature, when the number of already emitted signatures exceeds a predetermined number.
During a first step 41 of the procedure 40 , the chip card 7 receives the message M to be signed and a REPSEQ sequence number, and verifies the validity of the latter, for example by means of a signature generated by the certifying authority which is transmitted with the sequence number. This verification is carried out with a public key PK A of the certifying authority, stored by the chip card. If the signature associated with the sequence number is not valid, the chip card emits an error message (step 49 ) and the procedure terminates 40 without any signature being generated by the card.
If the signature is valid, the chip card proceeds to the following step 42 where it compares the received sequence number with a sequence number stored beforehand in the random access memory 13 , and if this number has not been stored beforehand, it stores it in step 43 .
In a first alternative, the maximum number of signatures NBSIG capable of being emitted is stored once and for all in the random access memory 13 of the card; this number may depend on the type of the card. Thus, for an application to transportation tickets, cards for 10 passages and others for 20 passages may be provided.
In another alternative, the maximum number of signatures capable of being emitted is transmitted with the sequence number and included in the signature which is verified by the chip card in step 41 . In this case, the signature generated by the certifying authority and received by the chip card may concern the sequence number concatenated with the number of authorized signatures and the current date: (REPSEQ∥NBSIG∥date).
In either alternative or in both, the chip card executes an additional step 44 for resetting a CPT counter with the received number of authorized signatures NBSIG at each change of sequence number.
In the following step 45 which is executed in both alternatives described hereinbefore and if the stored sequence number is identical with the received sequence number (step 42 ), the number of signatures capable of being generated NBSIG is decremented in the read only memory 13 . If the obtained number is strictly negative (step 46 ), the chip card emits an error message (step 49 ). In the contrary case, the chip card computes in step 47 a signature S i of the message M according to one of the list signature methods described hereinbefore, and emits the generated signature S i (step 48 ).
The card may also manage a different counter per sequence number. Every time the card receives a new sequence number and if need be, a maximum number of signatures NBSIG (if the latter may be different for each sequence number), it resets a CPT counter which is stored in a table in association with the sequence number. When the card receives a sequence number with a message to be signed, it looks up in this table whether the received sequence number is stored therein, and if this is the case, it updates the associated counter in order to take the new generated signature into account.
The list signature method which has just been described may be applied to an electronic voting method. The electronic voting method according to the invention comprises several phases including the execution of the procedures of the list signature method described hereinbefore.
This method involves the intervention of a certifying authority who organizes the elections, who executes for this purpose a procedure 50 for organizing the poll. This procedure consists of generating the data required for the elections to take place properly, a public database accessible to all, in which the ballots are collected. During the organization of the poll, scrutineers are also designated who will count the votes and determine the result of the election.
The organizing authority first of all proceeds with generating the different parameters required for setting up a list signature. The voters must then register beforehand, for example in a town hall on an election list so as to receive a chip card 7 as described hereinbefore, containing all the required data, i.e., an identifier Id i for the member i, a list signature secret key SK L which is common to all the members of the list, and a secret key SK i only known to the chip card and specific to the latter. By means of these parameters, the voters may participate in all future elections.
In step 51 of the procedure 50 , the organizing authority also publishes a sequence number m required for setting up a new list signature sequence, so as to prevent the voters for voting (signing) twice in this election.
Moreover, scrutineers responsible for counting the ballots will create 52 the required pairs of public/private keys. So that they should all cooperate in order to be able to decrypt an encrypted message with the public key. For this purpose, the cryptographic system set up is selected so as to allow a voter to encrypt a message (ballot) by means of at least one public key, while imposing cooperation of all the scrutineers to use the corresponding private key(s), and thereby decrypt the message.
The sharing of the decryption private key among all the scrutineers may be performed in the following way.
Let us consider g a generator of the cyclic group G. A respective private key x i is assigned to each scrutineer i who calculates the number y i belonging to G such that:
y i =g x i (1)
The public key Y to be used by the voters is obtained by the following formula:
Y
=
∏
i
y
i
(
2
)
and the corresponding private key X shared by all the scrutineers i the following:
X
=
∑
i
x
i
(
3
)
It is possible to reach a similar result by proceeding with encryption by using all the respective public keys of the scrutineers. The decryption requires knowing all the corresponding private keys.
During the opening of the polling stations, each voter emits a ballot by executing on a terminal a procedure 60 . In step 61 , the voter selects his/her vote v i and encrypts the latter by means of the public key of the scrutineers in order to obtain an encrypted ballot D i . Next, he/she signs the encrypted ballot by means of the list signature method in order to obtain a signature S i . The ballot consisting of the set (D i , S i ) of the ballot and the signature is then published anonymously in a public database 4 .
In step 62 , the encryption of the ballot is performed by using an encryption algorithm, such as for example the algorithm of EI Gamal or Paillier. If the EI Gamal algorithm is applied, the encryption is performed by calculating the following numbers:
a j =v j Y r and b j =g r (4)
wherein r is pseudo-random element. The encrypted ballot v j then consists of the couple D j =(a j ,b j ). The voter E j then calculates 63 the list signature of the encrypted ballot S j =Sig list (a j ∥b j ), Sig list being the list signature as described hereinbefore, obtained by his/her chip card 7 , and being transmitted to the terminal 2 .
The voter E j has just generated his/her ballot (D j ,S j ), which is sent 64 to the public database 4 by means of an anonymous transmission channel, i.e., prohibiting the linking of a message transmitted to the emitter of the latter. The voter may for this purpose use a public terminal or a network of mixers.
At the end of the poll, the scrutineers carry out counting the votes by executing the procedure 70 on the terminal 3 . This procedure first of all consists of generating 71 the decryption private key X from their respective private keys x i and by means of formula (3). Next, in step 72 , they access the public database 4 of the ballots in order to obtain the ballots (D i ,S i ) and to decrypt them.
The actual decryption of the ballots consists for each emitted ballot (step 73 ) of verifying 74 the signature S i by executing the list signature verification procedure 40 described hereinbefore and if the signature is valid and unique (step 75 ), of decrypting 76 the encrypted ballot D j by applying the following formula:
v j =a j /b j x (5)
The ballots v j thereby decrypted and verified with the result of the corresponding verification are introduced 77 into the database 4 of the ballots, in association with the ballot (D j ,S j ).
The decryption private key X is also published in order to allow everybody to verify the counting of the ballots.
Once all the ballots have been counted, this procedure 70 calculates in step 78 the result of the election and updates the public database of the ballots by writing the result therein, and possibly the decryption private key X.
It is easy to see that the properties stated hereinbefore, required for setting up an electronic voting system, are verified by the method described above. Indeed, each voter can only vote once (the chip card can only emit a single signature for a given sequence number), if the maximum number of signatures likely to be emitted is set to 1.
Next, it is not possible to begin with counting the ballots before the end of the poll, if at least one of the scrutineers observes the rule, as the presence of all the scrutineers is required for counting a ballot. Finally, the result of the election may be verified by everybody as the scrutineers provide in the database all the required elements (in particular the counting private key) in order to proceed with such a verification, and the verification of a signature is accessible to everybody by using the public key PK L of the certifying authority. Thus, anybody may carry out the counting in the same way as the scrutineers and therefore make sure that it has been carried out properly.
The keys of the scrutineers are of course obsolete at the end of the poll, since they are published. | The invention relates to a method for generating a list signature for a message to be signed, said method comprising steps which are carried out by an electronic material support of a member of a list. During said step, the electronic material support only generates an electronic signature according to a sequence number supplied to the electronic material support by a certifying authority, according to evidence of belonging to the list of members, to data relating to the electronic material support, and optionally to a key of an authority qualified to lift the anonymity of the generated signature. | 7 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] The present application claims priority to provisional application 62/028,265 filed on Jul. 23, 2014, the disclosure of which is expressly incorporated herein by reference in its entirety.
FIELD OF THE INVENTION
[0002] The present invention relates to a method of preparing zeolites without the use of an organic structure directing agent. More specifically, the method involves interzeolite transformation without an organic SDA.
BACKGROUND
[0003] Aluminosilicate zeolites are crystalline microporous solids with diverse framework structures and void networks constructed by arrangements of SiO 4 4− and AlO 4 5− tetrahedral units. These materials are widely used in adsorption, catalysis, and ion-exchange processes. Zeolites are typically synthesized by hydrothermal treatment of amorphous aluminosilicate gels in the presence of inorganic (e.g. Na + , K + , etc.) or organic structure-directing agents (OSDA) in hydroxide or fluoride media. OSDA reagents, in particular, increase the cost and the environmental burden of many large-scale zeolite syntheses.
[0004] Much effort has been devoted to the development of OSDA-free synthesis protocols to decrease such costs and the emission of toxic species in the gaseous and water streams generated during the synthesis or the subsequent treatments required to decompose organic species contained within zeolite voids. Recently, several groups have reported improved protocols for seed-assisted hydrothermal synthesis of zeolites from amorphous aluminosilicate gels without the use of OSDA species. These methods use large concentrations of alkali cations to stabilize the target frameworks and, as a result, have succeeded mostly in the synthesis of Al-rich frameworks (Si/Al<10). Similar protocols remain unavailable for OSDA-free synthesis of target zeolites (e.g., CHA, STF, MTW, MFI etc.) with lower Al contents, which are often preferred because of their greater structural and acid site stability. In some instances, it is simply not possible to grow a given zeolite structure of interest (e.g., STF, MTW, etc.) at conditions with a Si/Al of less than 10, or even 7.
[0005] Zeolites are kinetically (but not thermodynamically) stable towards conversion to denser framework structures (e.g. α-quartz). As a result, their synthesis often involves the formation of structures of intermediate stability in the course of forming the ultimate target structures, which are often rendered stable only by the use of specific organic or inorganic cations. Transformations of one zeolite structure into another one—interzeolite transformations—have been explored because they can provide a strategy for the selective synthesis of specific structures, often with shorter synthesis times. The mechanistic details of such interzeolite transformations, however, remain unclear and predictions of their success largely empirical.
[0006] Most reported interconversions use OSDA moieties to induce the nucleation of frameworks that are in fact of lower framework densities and thus less stable than the parent zeolite, or to form structures that would not form at all without the presence of an OSDA. Several studies have used seeds to assist the formation of desired structures without the aid of OSDA species; others have induced interzeolite transformations in the presence of both seeds and OSDA. Successful interzeolite transformations without either seeds or OSDA have been reported only for zeolites with low Si/Al ratios (Si/Al ratio of less than 10, generally from 2-5). To date, target materials with higher Si/Al ratios (Si/Al>10) do not appear to have been synthesized via interzeolite transformations without the aid of OSDA species.
[0007] Providing a more facile and cost effective method for synthesizing high silica zeolites would be of great value to the catalysis industry.
SUMMARY OF THE INVENTION
[0008] Accordingly, provided is a method of converting lower framework density zeolites into high Si/Al ratio zeolites having a higher framework density value, without the use of an organic SDA. The method comprises providing the lower framework density zeolite to be converted into the higher framework density zeolite, and then converting the lower framework density zeolite into a high Si/Al ratio zeolite, e.g., a ratio of at least 10. The conversion is conducted in the absence of an OSDA. The conversion is generally achieved by direct hydrothermal synthesis. This process eliminates the costly SDA and the waste treatment at the plant. The process is therefore more cost efficient and less equipment intensive.
[0009] In essence, the present inventors have developed a strategy and a set of guiding rules for organic structure-directing agent (OSDA)-free synthesis of zeolites via interzeolite transformation protocols. More specifically, as an example, high-silica MFI (ZSM-5), CHA (chabazite), STF (SSZ-35) and MTW (ZSM-12) zeolites can be synthesized from FAU (faujasite) or BEA (beta) parent zeolites via these methods. The successful transformations require that kinetic hurdles are overcome while exploiting the thermodynamic tendency of microporous materials to increase their framework density (FD). Kinetic barriers to interzeolite transformations are overcome for zeolites without common composite building units (CBU) between parent and daughter zeolites through the use of seeds. The use of seeds are not generally required when the starting and final structures share CBU components in common. These interzeolite transformation phenomena appear to be pseudomorphic in nature. The conversions conserve the volume occupied by the parent crystals and lead to similar size and crystal shape in the daughter materials. Such phenomena reflect that the incipient nucleation of the new structures occur at the outer regions of the parent crystals and lead to the nucleation of mesoporosity during transformations, as a natural consequence of the space-conserving nature of the structural changes and of the higher density of the daughter frameworks.
BRIEF DESCRIPTION OF THE DRAWINGS
[0010] FIGS. 1A and 1B show X-Ray diffractograms of the products synthesized from parent BEA ( FIG. 1A ) and FAU ( FIG. 1B ) via (a, b) direct, (c) template-assisted and (d) seed-assisted (using MFI seeds (S 1 )) transformations. The synthesis was carried out at 423 K, NaOH/SiO 2 =0.35 (from BEA FIG. 1A ) and NaOH/SiO 2 =0.5 (from FAU FIG. 1B ) and H 2 O/SiO 2 =65 (from BEA FIG. 1A ) and H 2 O/SiO 2 =95 (from FAU FIG. 1B ) (Table 1).
[0011] FIGS. 2A , 2 B, 2 C and 2 D show TEM images of MFI seeds S 1 ( FIG. 2A ) and MFI seeds S 2 ( FIG. 2B ) and products synthesized via interzeolite transformations of parent FAU (Si/Al=40) using S 1 MFI seeds ( FIG. 3C ) and S 2 MFI seeds ( FIG. 2D ). The synthesis was carried out at 423 K, NaOH/SiO 2 =0.5, H 2 O/SiO 2 =95 for 40 h with 10% wt. MFI seeds.
[0012] FIG. 3 shows X-Ray diffraction patterns of the products synthesized via seed-assisted transformations of parent FAU (Si/Al=40) for synthesis time of (a) 4 h, (b) 8 h, (c) 20 h, (d) 24 h, (e) 29 h, and (f) 40 h. The synthesis was carried out at 423 K, NaOH/SiO 2 =0.5, H 2 O/SiO 2 =95 with 10% wt. MFI seeds (S 1 ).
[0013] FIGS. 4A-4F show TEM images of the products synthesized via seed-assisted transformations of parent FAU (Si/Al=40) for synthesis time of 0 h (parent FAU) ( FIG. 4A ), 4 h ( FIG. 4B ), 8 h ( FIG. 4C ), 20 h ( FIG. 4D ), 29 h ( FIG. 4E ), and 40 h ( FIG. 4F ).
[0014] FIG. 5 shows crystal size distributions of the parent FAU and product MFI (MFI F -S1), synthesized via seed-assisted transformations of parent FAU (Si/Al=40). The synthesis was carried out at 423 K, NaOH/SiO 2 =0.5, H 2 O/SiO 2 =95 for 40 h with 10% wt. MFI seeds (S 1 ).
[0015] FIG. 6 shows Ar adsorption and desorption profiles for product MFI (MFI F -S1) synthesized via seed-assisted transformations of FAU (Si/Al=40). The synthesis was carried out at 423 K, NaOH/SiO 2 =0.5, H 2 O/SiO 2 =95 for 40 h with 10% wt. MFI seeds (S 1 ).
[0016] FIG. 7 shows X-Ray diffractograms of the products synthesized via transformations of FAU and BEA mixtures in (a) seed-assisted with 50% BEA and seed-free with (b) 50% (c) 10%, and (d) 5% BEA. The synthesis was carried out at 423 K, NaOH/SiO 2 =0.45, H 2 O/SiO 2 =80 and 40 h with/without 10% wt. MFI seeds (S 1 ).
[0017] FIG. 8 shows X-Ray diffraction patterns of the products synthesized from transformations of FAU (Si/Al=40) at NaOH/SiO 2 ratio of (a) 0.50, (b) 0.68, and (c) 0.85 using 10% wt. CHA seeds. The synthesis was carried out at 423 K, H 2 O/SiO 2 =95 for 40 h.
[0018] FIG. 9A shows X-Ray diffractograms of the products synthesized via interzeolite transformations of parent FAU (Si/Al=40) with 10% wt. seeds of STF and its corresponding seeds used. FIG. 9B shows X-Ray diffractograms of the products synthesized via interzeolite transformations of parent FAU (Si/Al=40) with 10% wt. seeds of MTW and its corresponding seeds used. The synthesis was carried out at 423 K, NaOH/SiO 2 =0.68, H 2 O/SiO 2 =95 for 40 h.
[0019] FIG. 10 shows X-Ray diffraction patterns of the products synthesized by seed-assisted transformations of FAU (Si/Al=40) at various temperatures in the presence of 10% wt. STF seeds. The synthesis was carried out at NaOH/SiO 2 =0.5, H 2 O/SiO 2 =95 for 40 h.
[0020] FIG. 11 shows X-Ray diffractograms of the products synthesized via seed-assisted transformations of FAU (Si/Al=40) using 10 wt % (a) MFI, (b) CHA, (c) STF and (d) MTW seeds for synthesis time of 10 days. Syntheses were carried out at 423 K, NaOH/SiO 2 =0.5 (for MFI) and 0.68 (for CHA, STF, and MTW), and H 2 O/SiO 2 =95.
[0021] FIG. 12 shows X-Ray diffractograms of (a) CHA seeds and the products synthesized with 10 wt % CHA seeds from (b) amorphous Si and Al sources and (c) parent FAU. Syntheses were carried out at 423 K, 0.68NaOH: 1.0SiO 2 : 0.0125Al 2 O 3 : 95.0H 2 O for 40 h. The solid yield of products was 6% in (b) and 25% in (c).
[0022] FIG. 13 is a schematic representation of the proposed mechanism of seed-assisted interzeolite transformations of parent FAU to daughter MFI.
DETAILED DESCRIPTION OF EMBODIMENTS
[0023] The present method prepares a zeolite having a Si/Al ratio of at least 10. The method comprises providing a first zeolite, e.g., a parent zeolite, and then converting the first zeolite to a second zeolite, or target zeolite, having a higher framework density than the first zeolite, and a Si/Al ratio of at least 10. The Si/Al ratio of the second zeolite obtained upon conversion can be, for example, in the range of from 11-25, or can be 40 or greater. The entire conversion is conducted in the absence of an organic structure directing agent (OSDA).
[0024] By the absence of an organic structure directing agent is meant that the synthesis is free of soluble OSDA. The present synthesis need not use an OSDA reagent as in conventional synthesis. Thus there is no soluble OSDA in the synthesis. While seeds of a zeolite can be used, i.e., such seeds being as-made materials, externally added, it has been found that the SDA that may be associated with the seeds is trapped in the interior of the zeolites, and cannot get out of the zeolite to impact the synthesis. In other words, the new zeolite is not nucleated by liberated SDA from the seeds. There is no liberated SDA from the seeds, and the synthesis remains free of soluble SDA.
[0025] The conversion is generally conducted in a basic solution under hydrothermal conditions. The temperature used in the conversion process can be above the crystallization temperature of the first zeolite. The pH of the basic solution is greater than 7, and can range up to 11, or even 13. Seed crystals of the second zeolite can aid in the conversion, and are generally added to the first zeolite either prior to or during the conversion.
[0026] In one embodiment, the first zeolite comprises BEA or FAU. In one embodiment, the second zeolite comprises ZSM-5, SSZ-35, ZSM-12 or chabazite.
[0027] The present invention therefore, provides a method of synthesis of high-silica zeolites, where the Si/Al is at least 10, 11-25, and even at least 40. MFI, CHA, STF and MTW zeolites can be synthesized by the present OSDA-free interzeolite transformation methods. Parent zeolites, e.g., BEA, framework density (FD) 15.3; defined as T atom/nm 3 , where T stands for Si or Al atoms in the zeolite framework, or FAU, FD 13.3, can be transformed into target daughter structures such as MFI (FD 18.4), CHA (FD 15.1), STF (FD 16.9) and MTW (FD 18.2) via recrystallization in aqueous NaOH at hydrothermal conditions. Structures with lower framework densities can be successfully transformed into more stable high silica structures with higher framework densities. The framework density (FD) value can be an absolute value or a normalized value on the basis of a theoretical all-silica framework structure. Either can be used as the relative values will be consistent for reflecting higher or lower framework density values.
[0028] Concomitant kinetic hurdles can require the presence of a common CBU between parent and target structures or, in their absence, the addition of seeds. The addition of seeds can also secure the desired target structure. A plausible synthesis mechanism, pseudomorphic in nature, for seed-assisted transformations is consistent with the observed effects of the parent Si/Al ratio, the NaOH/SiO 2 ratio, and the required synthesis temperature and time, as well as with the crystal habit and intracrystal mesoporous voids in the daughter structures. The resulting concepts and strategies provide predictive guidance for synthesizing a broad range of zeolite frameworks in the direction dictated by thermodynamics and with kinetics mediated by either common structural units along the reaction coordinate or by seeds of the target product.
[0029] The general requirements for a successful transformation of parent to product zeolite are summarized as follows: (1) the target zeolite should be of higher framework density than the parent zeolite because the ascending framework density scale in the transformations due to thermodynamically-favored high framework density structures, (2) a target zeolite should be added as seed material in the synthesis, when the parent structure and desired product do not share common CBU, (3) the seeds generally would not be required in the presence of common CBU components as long as the synthesis conditions are optimized for the desired zeolite, (4) the use of high-silica parent zeolites is important because Si/Al ratio determine their ability to restructure and form high-silica product zeolites by pseudomorphic transformation approach, and in one embodiment, the FAU zeolite source has a Si/Al greater than 10, (5) the synchronization of the spalling of the seed fragments and restructuring of parent zeolite is required for successful transformations, (6) the NaOH/SiO 2 and Si/Al ratios of the synthesis gel play a key role in such synchronization and should be optimized because the parent or seed zeolites should not dissolve completely prior to their interaction with each other to nucleate the desired structure, and (7) the chemical composition of gel and synthesis conditions should be optimized, further, to get pure and highly crystalline zeolite products. The validity of these requirements is confirmed by the synthesis of high-silica CHA (FD 14.5), STF (FD 17.3) and MTW (FD 19.4) zeolites via interzeolite transformations of FAU (FD 13.3).
[0030] In practicing the present method, a balance of the conditions and components can provide improved products. For example, the NaOH content is balanced with the time and temperature used in the synthesis method. In the synthesis, in general, the silica and alumina are contributed by the source zeolite (e.g., FAU) and any seeds. When seeds are used, they can be greater than 5 wt % in the synthesis. The NaOH/SiO 2 ratio generally ranges from 0.25-1.00, and the H 2 O/SiO 2 ratio is generally greater than 50. The time for the synthesis in one embodiment ranges from about 10 to about 80 hours, and in one embodiment, the temperature can range from about 130 to about 160° C. The zeolite product made is generally metastable so too much of a given factor can result in a cascade reaction effect where a product with higher framework density than the desired product may result. For example, prolonged heating in some of the reactions can produce mixtures of quartz and mordenite, an aggregately denser product than what may be desired. Thus a balancing is needed to optimize the desired result, which one of ordinary skill in the art can do based on the discussion herein and the examples set for the below.
[0031] The following examples are provided for purposes of illustration of the present process, and are not meant to be limiting.
EXAMPLES
[0032] Materials used in the examples include fumed SiO 2 (Cab-O-Sil, HS-5, 310 m 2 g −1 ), NaOH (99.995%, Sigma Aldrich), FAU (CBV780, Zeolyst, H-FAU, Si/Al=40), FAU (CBV712, Zeolyst, NH 4 -FAU, Si/Al=6), BEA (CP811E-75, Zeolyst, H-BEA, Si/Al=37.5), BEA (CP814E, Zeolyst, NH 4 -BEA, Si/Al=12.5), and tetrapropylammonium bromide (TPABr, 98%, Sigma Aldrich) were used as received.
Seeds
[0033] In a typical synthesis, 649 g of water, 740 g of 1 mol dm −3 NaOH (Baker Reagent), 98 g of tetrapropylammonium bromide (Kodak Chemicals) were added to 872 g of Ludox AS-30 colloidal SiO 2 (Dupont). The synthesis mixture was then transferred into a Hastelloy-lined stainless steel autoclave (3.8 dm 3 ), pressure tested and held at 423 K for 4 days in a convection oven under rotation (78 rpm). After 4 days, the autoclave was cooled, and the resulting solid was collected by filtration and washed with deionized water (17.9 MΩ·cm resistivity) until the rinse liquids reached a pH of 7-8. The resulting product was crystalline MFI (confirmed by powder X-ray diffraction (XRD)) with Si/Al˜300 (by Inductively-coupled plasma atomic emission spectroscopy (ICP-AES) analysis) and ˜6μ sized zeolite crystals (by transmission electron microscopy (TEM)). These MFI seeds (S 1 ) were used in all seed-assisted interzeolite transformations from FAU to MFI unless mentioned otherwise. MFI (S 2 ) was synthesized by dissolving Al(OH) 3 (53% Al 2 O 3 , Reheis F-2000 dried gel, 0.44 g) in a solution containing deionized H 2 O (38 g), tetrapropyl ammonium hydroxide (TPAOH, 40 wt %, Aldrich, 7.5 g) and KOH (1 M solution in deionized H 2 O, Fisher, 15 g). Ludox AS-30 colloidal silica (18 g) was added to the solution and the mixture was then transferred into a Teflon-lined stainless steel autoclave (Parr, 125 cm 3 ) and held at 423 K for 3 days under static conditions. The resulting solids were collected by filtration through a fritted disc Buchner filter funnel (Chemglass, 150 ml, F) and washed with deionized water (17.9 MΩ·cm resistivity) until the rinse liquids reached a pH of 8-9 and the sample was heated in convection oven at 373 K overnight. In the present examples, the material used as seeds were prepared using previously described synthesis procedures for CHA 1 , STF 2 and MTW 3 zeolites. See, (1) Zones, S. I. U.S. Pat. No. 8,007,763 B2, Aug. 30, 2011, (2) Musilova-Pavlackova, Z., Zones, S. I., Cejka, J. Top. Catal. 2010, 53, 273; (3) Jones, A. J., Zones, S. I., Iglesia, E. J. Phys. Chem. C 2014, 118, 17787.
Example 1
[0034] In a typical synthesis, zeolite BEA or FAU was added (0.5-1.0 g) to an aqueous NaOH solution, into which the MFI seed crystals or structure-directing agents (TPABr) were added to prepare final mixtures with molar compositions listed in Table 1. These mixtures were placed within sealed polypropylene containers (Nalgene, 125 cm 3 ) and homogenized by vigorous magnetic stirring (400 rpm; IKA RCT Basic) for 1 h at ambient temperature. The mixture was then transferred into a Teflon-lined stainless steel autoclave and held at 423 K for 24-40 h under static conditions. The resulting solids were collected by filtration through a fritted disc Buchner filter funnel (Chemglass, 150 ml, F) and washed with deionized water (17.9 MΩ·cm resistivity) until the rinse liquids reached a pH of 8-9. The sample was heated in a convection oven at 373 K overnight. The solid yields of the resulting products were defined as
[0000]
Yield
(
%
)
=
Product
(
g
)
Parent
zeolite
(
g
)
+
seeds
(
g
)
×
100
(
1
)
[0035] The samples were then treated in a tube furnace in flowing dry air (1.67 cm 3 g −1 s −1 ) to 773 K at 0.03 K s −1 and held at this temperature for 3 h. The samples, after treatment, were denoted as MFI B -D, MFI B -T, MFI B -S, when synthesized from BEA, and MFI F -D, MFI F -T, MFI F -S, when synthesized from FAU, in the direct (-D), template-assisted (-T), and seed-assisted (-S) interzeolite transformations, respectively.
[0000]
TABLE 1
Initial synthesis molar compositions, product phase, yield, and final
pH of samples for synthesis of MFI a .
Sample
Parent zeolite
NaOH/
H2O/
Time
Additional
Product d
Final
Yield e
Name
(Si/Al)
SiO 2 b
SiO 2 b
(h)
(OSDA/Seed) e
(Si/Al)
pH
(%)
MFI B -D1
BEA(12.5)
0.35
65
24
—
Am.
—
—
MFI B -D2
BEA(37.5)
0.35
65
24
—
MFI (22)
11.8
46
MFI B -T
BEA(37.5)
0.35
65
24
TPABr (0.05) f
MFI (35)
12.5
47
MFI B -S
BEA(37.5)
0.35
65
24
10% wt. MFI Seeds
MFI (23)
11.8
47
MFI F -D1
FAU(6)
0.50
95
40
—
Am.
—
—
MFI F -D2
FAU(40)
0.50
95
40
—
Am.
—
—
MFI F -T
FAU(40)
0.50
95
40
TPABr (0.05) f
MFI (33)
12.5
58
MFI F -S1
FAU(40)
0.50
95
40
10% wt. MFI Seeds
MFI (22)
11.8
47
MFI F -S2
FAU(40)
0.23
95
40
10% wt. MFI Seeds
MFI (42)
11.7
76
MFI F -S3
FAU(40)
0.85
95
40
10% wt. MFI Seeds
MFI (11)
12.0
18
a T = 423K for all the syntheses.
b Reported values excludes the SiO 2 amount present in seed materials.
c Seed ( wt . % ) = Seed material ( g ) Parent zeolite ( g ) × 100 d Am. = Amorphous
e yield ( % ) = Product ( g ) Parent zeolite ( g ) + seed ( g ) × 100 f Values in parentheses show molar composition of TPABr relative to SiO2 amount of parent zeolite.
Example 2
[0036] The synthesis of CHA, STF, and MTW zeolites was achieved by interzeolite transformations of FAU as parent zeolite. FAU (0.5-1.0 g) was added to an aqueous NaOH solution to achieve molar compositions of x NaOH: 1.0SiO 2 : 0.0125Al 2 O 3 : 95H 2 O (x=0.50, 0.68, 0.85), into which 10% wt. (% wt. based on parent FAU) seed crystals (CHA, STF, or MTW) were added to prepare final mixtures with molar compositions listed in Table 2. These mixtures were placed within sealed polypropylene containers (Nalgene, 125 cm 3 ) and homogenized by vigorous magnetic stirring (400 rpm; IKA RCT Basic) for 1 h at ambient temperature. These mixtures were then transferred into a Teflon-lined stainless steel autoclave and held at the desired crystallization temperature (423, 428, or 433 K) for 40 h under static conditions. The resulting solids were collected by filtration through a fritted disc Buchner filter funnel (Chemglass, 150 ml, F) and washed with deionized water (17.9 MΩ·cm resistivity) until the rinse liquids reached a pH of 7-8. The samples were heated in a convection oven at 373 K overnight. The samples were then treated in tube furnace in flowing dry air (1.67 cm 3 g −1 s −1 ) to 873 K at 0.03 K s −1 and held at this temperature for 3 h. The resulting samples after treatment were denoted as CHA F -S, STF F -S, MTW F -S, synthesized via interzeolite transformations of FAU using seeds of CHA, STF, and MTW, respectively.
[0037] For the synthesis of the H-form of these zeolites, the treated Na-zeolites were added to an aqueous NH 4 NO 3 solution with stirring at 353K for 4 h. The process was repeated two more times to recover NH 4 -zeolites, which was treated in a tube furnace in flowing dry air (1.67 cm 3 g −1 s −1 ) to 873K at 0.03 K s −1 for 3 h to form H-zeolite.
[0000]
TABLE 2
Initial synthesis molar compositions, product phase, yield, and
final pH of samples for transformations of FAU using CHA, STF and MTW seeds a .
Sample
Parent
NaOH/
Temp
Seeds c
Product
Product
Final
Yield e
Crystallinity
Name
(Si/Al)
SiO 2 b
(K)
(10% wt.)
Phase d
(Si/Al)
pH
(%)
(%)
CHA F -S1
FAU(40)
0.50
423
CHA
CHA + Am.
19
11.8
46
50
CHA F -S2
FAU(40)
0.68
423
CHA
CHA + Am.
11
11.7
25
66
CHA F -S3
FAU(40)
0.85
423
CHA
CHA + MOR
12.2
22
CHA F -S4
FAU(40)
0.50
428
CHA
CHA + Am.
11.9
49
STF F -S1
FAU(40)
0.50
423
STF
STF + Am.
11.8
47
STF F -S2
FAU(40)
0.50
428
STF
STF + Am.
11.8
48
STF F -S3
FAU(40)
0.50
433
STF
STF + MFI
12.0
52
STF F -S4
FAU(40)
0.68
423
STF
STF + AM
11
11.7
26
78
STF F -S5
FAU(40)
0.85
423
STF
STF + MOR
12.0
33
MTW F -S1
FAU(40)
0.50
423
MTW
MTW + Am.
11.9
44
MTW F -S2
FAU(40)
0.50
428
MTW
MTW + Am.
11.8
48
MTW F -S3
FAU(40)
0.68
423
MTW
MTW + Am.
12
12.0
29
60
a H 2 O/SiO 2 = 95 and synthesis time = 40 h for all the syntheses.
b Reported values excludes the SiO2 amount present in seed materials.
c Seed ( wt . % ) = Seed material ( g ) Parent zeolite ( g ) × 100 d Am. = Amorphous
e
yield
(
%
)
=
Product
(
g
)
Parent
zeolite
(
g
)
+
seed
(
g
)
×
100
Example 3
[0038] The identity and phase purity of the product zeolites were demonstrated by powder XRD measurements (Cu Kα radiation λ=0.15418 nm, 40 kV, 40 mA, Bruker D8 Advance). Diffractograms were collected for 2θ values of 5-35° at 0.02° intervals with a 2 s scan time. Si, Al, and Na contents of the samples were measured by ICP-AES (IRIS Intrepid spectrometer; Galbraith Laboratories). TEM images were taken on Philips/FEI Tecnai 12 microscope operated at 120 kV. Before TEM analysis, the samples were suspended in ethanol and dispersed onto ultrathin carbon/holey carbon films supported on 400 mesh Cu grids (Ted Pella Inc.). Argon (Ar) adsorption-desorption measurements of zeolite products were performed on Quantachrome Autosorb-1 at 87 K. Prior to the measurements, all samples were degassed at 623 K for 4 h under vacuum. The final pH values were measured at ambient temperature using an Orion Ross combination electrode (Orion 8103BNUMP) with an Orion Star A215 meter (calibrated using buffer solutions of pH 7.00, 10.01 and 12.00).
Example 4
[0039] Parent BEA zeolites with low Si content (Si/Al=12.5) formed only amorphous solids in aqueous NaOH (NaOH/SiO 2 =0.35, H 2 O/SiO 2 =65; Table 1) at 423 K under hydrothermal conditions (X-ray diffractogram; FIG. 1A (a), apparently because MFI frameworks preferentially form in gels with high Si/Al contents, because abundant five-membered rings in MFI are disfavored at high Al contents.
[0040] MFI crystals readily formed, however, from parent BEA zeolites with lower Al contents (Si/Al=37.5; (X-ray diffractogram; FIG. 1A (b), 46% yield (Eq. 1); Table 1), in aqueous NaOH solution (NaOH/SiO 2 =0.35, H 2 O/SiO 2 =65; Table 1) under autogenous pressures at 423 K. Interestingly, this transformation occurred spontaneously, without requiring the presence of any seeds or OSDA. The Si/Al ratio in the MFI product (Si/Al=22; Table 1) was much lower than in the parent BEA (Si/Al=37.5) and the solids yield was 46% (Table 1) suggesting that nearly all of the Al in the parent BEA was incorporated into the product MFI, whereas some SiO 2 remained dissolved in solution. Crystalline MFI was obtained (X-ray diffractograms; FIG. 1A (c) and FIG. 1A (d), 47% yield (Eq. 1) for both, also, from template-assisted (with TPABr) and seed-assisted (with 10% wt. MFI seeds) transformations of parent BEA (Si/Al=37.5). Thus, it can be concluded that parent BEA with high Si content (Si/Al=37.5) transformed to MFI spontaneously and in the individual presence of MFI seeds or OSDA at Si/Al ratios in the parent BEA that favor MFI frameworks.
[0041] It is noted that the framework structures and composite building units (CBU) of the parent BEA and product MFI include a common mor structural motif. It seems plausible, therefore, that a CBU, present in BEA and required to form MFI, remains essentially intact within BEA-derived intermediates during the conversion of BEA to MFI. This CBU may assist the local nucleation of MFI and in doing so, minimize inherent kinetic hurdles and allow BEA to MFI transformations to occur without seeds or OSDA. This common CBU serves as a kinetic mediator for nucleating the daughter structure, suggesting that zeolites containing common CBU may be able to overcome kinetic barriers that obstruct their interconversions in the direction dictated by the thermodynamic tendency of zeolites to form structures with greater framework densities. MFI zeolites were obtained after 24 h from parent BEA zeolites ( FIG. 1A ), while hydrothermal MFI syntheses from amorphous aluminosilicate gels, with or without OSDA, typically require 2-15 days. Thus, the presence of the BEA structure, plausibly because of its common CBU with MFI, shortens synthesis times because of more rapid nucleation.
Example 5
[0042] Parent FAU zeolites with Si/Al ratios of 6 and 40 gave only amorphous solids in hydrothermal aqueous NaOH environments (NaOH/SiO 2 =0.5, H 2 O/SiO 2 =95; Table 1) at 423 K (X-ray diffractograms; FIG. 1B (a) and FIG. 1B (b), consistent with kinetic hurdles that cannot be overcome in spite of favorable thermodynamics (FAU, FD 13.3; MFI, FD 18.4), possibly because of the lack of common CBU. MFI formed, however, when FAU (Si/Al=40) was treated in similar hydrothermal environments but with MFI seeds in the synthesis mixture (X-ray diffractograms; FIG. 1B (c) and FIG. 1B (d), 58 and 47% yield (Eq. 1), respectively; Table 1). These results contrast the ability of BEA precursors to form MFI even in the absence of such kinetic mediation. Seeds are required in the case of parent FAU zeolites to assist the nucleation of the favored MFI structures.
[0043] FIGS. 2A , 2 B, 2 C and 2 D show TEM images of two MFI seeds of different crystal size (6 μm; seed S 1 ; FIG. 2A and 0.2 μm; seed S 2 ; FIG. 2B ) and of the MFI products formed from FAU parent zeolites using each of these seeds ( FIGS. 2C and 2D , respectively). The crystal habit and size of the MFI products using S 1 (TEM, FIG. 2C ) and S 2 (TEM, FIG. 2D ) seeds are similar (˜0.7 μm diameter) and differ markedly from those of the MFI seeds used (TEM, FIGS. 2A and 2B ), which do not remain intact as they mediate MFI nucleation from parent FAU crystals. These seeds do not serve as intact nucleation sites, but instead provide CBU or shed small fragments, as in the case of homogeneous nucleation and growth during seed-assisted hydrothermal synthesis from amorphous aluminosilicate gels. The products crystals are in fact smaller (˜0.7 μm crystals, FIG. 2C ) than the S 1 seed crystals (˜6 μm crystals, FIG. 2A ), making epitaxial growth of MFI crystals onto seeds implausible.
[0044] FAU diffraction lines disappeared after synthesis times of 4 h, while MFI lines were detectable at all times (4-40 h; FIGS. 3B-3F ). The amorphous background in the diffractograms ( FIGS. 3A-3F ; 2θ=20-30°) disappeared and the MFI diffraction lines were the only discernible features after 24 h. These data indicate that FAU crystals lose their long-range order in the NaOH media in a time scale that still preserves the identity of MFI seeds, which provide essential components for the ultimate recrystallization of FAU parent structures into MFI. The size and shape of MFI crystals, formed from seed-assisted FAU conversion to MFI, did not change significantly during synthesis (4-40 h; TEM; FIGS. 4B-4F ) and resemble those of the parent FAU zeolite (TEM; FIG. 4A ). MFI mean crystal sizes are only slightly larger than in the FAU parent zeolites (crystal size histograms; FIG. 5 ). This is consistent with a seed-assisted growth in which FAU structure swell to form structures without local order and spalled MFI fragments from MFI seeds induce the nucleation of MFI frameworks at their outer surfaces, thus fixing an outer crust that preserves the habit and size of the parent crystals (see FIG. 13 ).
[0045] Such volume-conserving (pseudomorphic) transformations reflect the exclusive contact of seed fragments with the outer surface of locally disrupted, but otherwise intact, FAU domains, which nucleate MFI from the outer to the inner regions of these FAU domains. The pseudomorphic nature of these processes requires the nucleation of voids to account for the increase in framework density inherent in FAU to MFI transformations. The mechanistic hypothesis depicted in FIG. 13 suggest that successful transformations would require the synchronization of the local disruption of the FAU structure and the shedding of nucleating fragments from MFI seeds. The requirement for high-silica FAU parent zeolites to form high-silica MFI products implicates such synchronization.
[0046] Ar adsorption and desorption measurements ( FIG. 6 ) of the product (after 40 h), synthesized from transformations of FAU using MFI seeds, show a hysteresis after P/P o value of 0.4, which is indicative of the presence of mesopores in the sample. No hysteresis was observed in the Ar adsorption-desorption curves of the product if MFI is grown from a reaction with hydrogel components in the typical zeolite synthesis conditions. These Ar adsorption-desorption measurements, therefore, confirm the presence of mesopores in the MFI product, which is, both, interesting and unique because the mesopores are formed by one-pot synthesis and do not require any post-synthesis treatments such as desilication or dealumination, that are typically used to create mesopores. Such mesopores are useful in practice because they decrease the diffusion distances prevalent for intact crystals.
[0047] FAU-derived species retain their physical integrity, and incipient nucleation of the target product structures occurs at the outer regions of the parent crystals by spalled subunits or CBU species derived from MFI seeds, which retain the local MFI structure required to assist the transformation of FAU-derived domains into MFI crystals. The space conserving nature of the transformation requires, in turn, the nucleation of mesoscopic voids within the formed MFI crystals because their framework density is higher than that of the parent FAU.
Example 6
[0048] BEA to MFI transformations occur spontaneously, without any significant kinetic hindrance, and even in the absence of MFI seeds. In contrast, MFI seeds are useful to convert FAU to MFI to provide the kinetic mediation required in the absence of any common CBU. Thus, it is plausible that BEA and FAU mixtures, without seeds, can transform to MFI by in-situ generation of MFI seeds or by assistance through mor structural units of BEA (common to MFI).
[0049] MFI products were obtained in the transformations of 50-50% wt. FAU-BEA mixture with 10% wt. MFI seeds (X-ray diffractogram; FIG. 7 ( a )), as expected, and also in the direct transformations (X-ray diffractogram; Fig. (b)), in the absence of MFI seeds. MFI products were obtained, further, from transformations of 90-10 and 95-5% wt. FAU-BEA mixtures without seeds (X-ray diffractograms; FIG. 7( c ), ( d )), with similar yields (46-48%) as those observed in transformations of BEA or FAU alone (46-47%, Table 1).
[0050] This data suggest that BEA can assist in the nucleation of MFI from FAU, either by providing the mor structural unit (common to MFI) or by in-situ generation of MFI seeds from direct transformations of BEA.
[0051] These results indicate practical applications of interzeolite transformation protocols as this suggest that expensive seed materials or OSDA are not required as long as a source is present that can generate the desired seeds, in-situ, during the synthesis. In addition, these results are consistent with proposed synthesis guidelines, which suggest that the presence of CBU common with product or product seeds, in the synthesis, help to overcome the kinetic barriers for the synthesis of thermodynamically-favored zeolites, denser than parent structures.
Example 7
[0052] FAU (Si/Al=40) converted to amorphous solids in the absence of any seeds (0.5NaOH: 1.0SiO 2 : 0.0125Al 2 O 3 : 95H 2 O; Table 1), as described previously in Example 5 (X-ray diffractograms; FIGS. 1A and 1B ), indicating the synthesis conditions needs to be optimized to be able to get desired crystalline products. In the absence of such optimization, use of CHA seeds in the synthesis should, however, form CHA products. CHA zeolite (Si/Al=19) formed, indeed, by transformations of parent FAU using 10% wt. CHA seeds at 423 K (0.5NaOH: 1.0SiO 2 : 0.0125Al 2 O 3 : 95H 2 O; Table 2) for 40 h of synthesis (X-ray diffractogram; FIG. 8 ). The synthesis conditions (with CHA seeds) are same as those used for BEA or FAU to MFI transformations. The solid yield of the resulting product was 46% (Table 2), which is almost the same as that of MFI synthesized via seed-assisted transformations of FAU or BEA (46-47%; Table 1). The resulting products, however, seem to contain some amorphous solids indicated by the broad background signal in 20-30 degree 20 range ( FIG. 8 ), suggesting the improper synchronization of decomposition of CHA seeds and parent FAU, apparently because of the lower Si content of CHA seeds (Si/Al=15) than MFI seeds (Si/Al˜300), which make CHA harder to decompose at the synthesis conditions (Table 2).
[0053] CHA products formed, also, for NaOH/SiO 2 ratio of 0.68 ( FIG. 8 ). The crystallinity of these products (66%; Table 2) was higher than those synthesized at NaOH/SiO 2 ratio of 0.50 (50%; Table 2) possibly because of the better synchronization of CHA decomposition and restructuring of FAU due to higher NaOH/SiO 2 ratio of the synthesis gel and in turn, high solution pH, which increase the solubility of parent FAU and CHA seed materials. The solid yields (Table 2), in turn, decreased from 46% to 25% and so the Si/Al ratio of product from 19 to 11 also because of the high synthesis pH, at which Si species prefers to be in solution due to high solubility. The increase in the NaOH/SiO 2 ratio, further, to 0.85, lead to the formation of MOR phase, as byproduct, along with CHA ( FIG. 8 ), indicating that very high NaOH concentration of the synthesis gel causes rapid nucleation of multiple phases in the solution due to fast dissolution of parent or seed materials, followed by their rapid crystal growth; thus, very high NaOH/SiO 2 ratios are undesirable for the formation of pure zeolite phases via these methods. Thus, the synthesis of high-silica CHA (Si/Al=11) was achieved from transformations of FAU with CHA seeds, using the developed synthesis guidelines; there is further scope, however, for optimizing the synthesis parameters to get highly crystalline CHA. Amorphous aluminosilicate gels under similar synthesis conditions (0.68NaOH: 1.0SiO 2 : 0.0125Al 2 O 3 : 95H 2 O) with 10 wt % CHA seeds led to a mixture of CHA and MOR zeolites as products with only 6% yield (Figure S 1 ), confirming that the parent FAU zeolites in these transformations do not dissolve completely and form amorphous aluminosilicate species. The results are shown in FIG. 12 .
Example 8
[0054] STF and MTW zeolites formed (X-ray diffractograms; FIG. 9 ) in aqueous NaOH from transformations of parent FAU using STF and MTW seeds, respectively, at 423 K for 40 h of synthesis (0.5NaOH: 1.0SiO 2 : 0.0125Al 2 O 3 : 95H 2 O; Table 2), synthesis conditions same as those used for FAU to MFI transformations. The resulting products, however, had poor crystallinity, indicated by broad background for amorphous solids in the diffractograms ( FIGS. 9A and 9B ). The NaOH/SiO 2 ratio of the synthesis gel was, therefore, varied from 0.50-0.85. Results, similar to CHA, were reached for STF and MTW zeolites, where the NaOH/SiO 2 ratio of 0.68 resulted in highest crystallinity of pure desired zeolite phases (X-ray diffractograms; FIGS. 9A and 9B ). High silica STF (Si/Al=20) and MTW (Si/Al=30) products formed from transformations of FAU (0.68NaOH: 1.0SiO 2 : 0.0125Al 2 O 3 : 95H 2 O; Table 2) with solid yields of 26% and 29%, respectively (Table 2), which are similar to that of CHA formed from FAU at same synthesis conditions (Si/Al=11, 25% yield, Table 2). The crystallinity of STF and MTW samples were 78 and 60% (Table 2), respectively.
[0055] The increase in synthesis temperature from 423 K to 428 K, in the transformations of FAU using STF seeds, had no significant effect on the product crystallinity (X-ray diffractogram, FIG. 10 ), indicated by no detectable change in diffraction line intensities, yields and Si/Al ratio of the resulting products (Table 2) formed after the same synthesis time (40 h). Further increase of synthesis temperature from 428 K to 433 K, however, drove the transformations to more dense zeolite structure, MFI (X-ray diffractogram, FIG. 10 ); suggesting the products from these transformations are kinetically trapped. The hypothesis of kinetic trapping of products was also verified by increasing the time of synthesis, which should also drive the transformations further to more dense structures. Products from transformations of FAU using MFI, CHA, STF or MTW seeds converted to denser structures as time proceeded and led to mixtures of dense zeolite phases after 10 days of synthesis (X-ray diffraction patterns; FIG. 11 ). This data confirm that products of the interzeolite transformations are kinetically trapped structures for a certain set of synthesis conditions and that these structures, with time or temperature, will convert to thermodynamically more stable structures (more dense phases). These transformations, taken together, provide evidence for the key role of Si/Al ratio of the parent zeolite to determine their ability to restructure and form high-silica zeolites, of NaOH to SiO 2 ratios of the synthesis gel to ensure the synchronized decomposition of parent and seeds and of temperature and time to kinetically trap the desired structures. Synthesis of high-silica CHA, STF and MTW zeolites support the validity of the synthesis guidelines; further optimizations of the synthesis compositions and conditions are, however, required to form highly crystalline products. We expect that the developed interzeolite transformation protocols for the synthesis of high-silica zeolites can be extended further to zeolites of different frameworks, void environments and framework compositions, based on their framework density and CBU components. This method not only synthesizes zeolites without OSDA, but also forms mesoporous crystals, which are known to improve the accessibility of reactants to the zeolite micropores and thus, have the potential to enhance the turnover rate of reactions and tune the reaction selectivity.
[0056] In summary, a method for the synthesis of useful high-silica zeolites such as MFI, CHA, STF, and MTW via OSDA-free interzeolite transformation has been provided. Parent zeolites of low framework densities e.g. FAU or BEA, can be are transformed to daughter zeolites of higher framework densities, e.g., MFI, CHA, STF, and MTW via recrystallization in aqueous NaOH at hydrothermal conditions. Successful transformations require that the kinetic hurdles are overcome while exploiting the thermodynamic tendency of microporous solids to increase their framework density. Transformation of BEA to MFI can occur spontaneously without any significant kinetic and thermodynamic hurdles, while the conversion of FAU to MFI, CHA, STF and MTW required product seeds, suggesting the absence of sufficient kinetic driving forces in these cases. The seed-assisted interzeolite transformations were proposed to be pseudomorphic in nature. Such conversions conserve the volume occupied by the parent crystals and lead to similar size and crystal shape in the product zeolites. The incipient nucleation of the new structures occur at the outer regions of the swollen parent crystals and lead to the nucleation of mesoporosity during transformations due to the space-conserving nature of the pseudomorphic transformations and of the higher density of the daughter frameworks. The successful transformations also seemed to require the synchronization of loosening of parent and spalling of seeds, the absence of which lead to amorphous solids. The synthesis mechanism and developed guidelines enable one to design the synthesis conditions of desired zeolites and would expand the diversity of framework types of zeolites that can be synthesized by these methods.
[0057] In particular, the present method allows one to make a stable OSDA-free zeolite having a Si/Al above about 7, and even above 10. While the prior art exemplifies the making of materials with a Si/Al of 6 or less without an SDA in the synthesis, products at higher Si/Al are not stable without a SDA filling the empty spaces in the zeolite product, as there are fewer hydrated cations to do so as the overall aluminum content is dropping. Higher Si/Al products also usually have more 5-rings in structure, which do not like aluminum. To the contrary, the present synthesis allows one to make a stable zeolite having a Si/Al greater than 10 without the use of soluble SDA in the synthesis. For example SSZ-35 can be made SDA-free. Such SSZ-35 is loaded with 5-rings and has a Si/Al close to 25. The present synthesis therefore provides one with a more facile and cost effective method for synthesizing high silica zeolites.
[0058] The above specification, examples and data provide a complete description of the method of the present invention. Since many additional embodiments of the invention can be made without departing from the spirit and scope of the invention, the invention resides in the claims provided hereto. | Provided is a method for preparing a zeolite having a Si/Al ratio of at least 10 by interzeolite transformation in the absence of an organic structure directing agent. The method is more cost effective and less equipment intensive as it eliminates the costly organic structure directing agent and the waste treatment at the plant. | 2 |
BACKGROUND OF INVENTION
1. Field of the Invention
This invention relates to the production of rubber-modified monovinyl aromatic polymers, and more particularly, to a method and apparatus for making high impact polystyrene (HIPS) by continuously polymerizing butadiene, exchanging the hydrocarbon solvent used in the butadiene polymerization with styrene, and feeding the resultant polybutadiene/styrene stream to a conventional HIPS production line.
2. Description of Related Art
Methods and apparatus for continuously producing polybutadiene and for producing high impact polystyrene using polybutadiene as the rubber component, are both well known. The solution polymerization of butadiene to polybutadiene in a hydrocarbon solvent is disclosed, for example, in U.S. Pat Nos. 4,271,060; 4,375,524; 4,495,028; and 4,686,086, the written descriptions of which are incorporated herein by reference. According to conventional methods, polybutadiene is made by polymerizing butadiene to about 12 weight percent solids in hexane, butane, cyclopentane, cyclohexane, or another hydrocarbon solvent; concentrating the mixture to about 30 weight percent solids by flashing off solvent; steam stripping with soap to remove additional solvent, reduce stickiness and precipitate the crumb rubber; squeezing and drying to remove excess moisture; and agglomerating the dried crumb rubber by the addition of heat to produce irregularly shaped bales. The baled rubber is then sent to intermediate storage or transported to plant sites for use in making other products such as rubber-modified polymers.
One widely used rubber-modified polymer is high impact polystyrene (HIPS). HIPS is made by polymerizing styrene monomer having dissolved in it from about 1 to about 15 percent by weight styrene-butadiene rubber (SBR) or polybutadiene rubber. Both are commonly produced with Mooney viscosities of either 35 or 55, and polybutadiene is generally less expensive than SBR. A conventional method for making HIPS using polybutadiene is disclosed, for example, in U.S. Pat. No. 4,777,210 to Sosa and Nichols, the entire written description of which is incorporated herein by reference.
When bales of polybutadiene made by conventional, prior art methods are used in HIPS production, they are segmented or chopped and ground, then dissolved in a solvent/styrene mixture prior to initiating polymerization of the styrene monomer. Because the labor, equipment, transportation, storage and energy costs associated with finishing the polybutadiene bales and later grinding and dissolving the rubber for use in making HIPS are significant and desirably avoided if possible, a method and apparatus are needed for continuously producing and supplying a polybutadiene/styrene stream to a conventional HIPS production line.
SUMMARY OF THE INVENTION
According to the present invention, methods and apparatus are provided for polymerizing butadiene into polybutadiene, continuously exchanging styrene monomer for the solvent used to produce the polybutadiene, and polymerizing the resultant polybutadiene/styrene stream into high impact polystyrene.
According to one preferred embodiment of the invention, apparatus is provided for producing HIPS that comprises, as a polybutadiene feed source, butadiene and solvent preparation means, additive metering means, butadiene polymerization means, solvent exchange means and solvent recovery means.
According to another preferred embodiment of the invention, a method is provided for making HIPS using polybutadiene, the method preferably comprising the steps of introducing sufficient butadiene to produce a polybutadiene solids level of from about 1 to about 15 weight percent and most preferably about 12 weight percent after polymerization, a suitable preheated hydrocarbon solvent, and a suitable polymerization catalyst into a continuous-stirred tank reactor (CSTR); polymerizing these components; discharging them from the CSTR into a plug-flow reactor (PFR) to complete polymerization of the butadiene; introducing styrene monomer into the stream; mixing, heating and flashing off the solvent and unreacted butadiene monomer by two-stage vacuum devolatilization to produce a polybutadiene/styrene solution; and thereafter polymerizing the solution to produce polystyrene containing dispersed rubbery particles.
The method and apparatus disclosed herein are believed to be useful for producing HIPS containing high-quality polybutadiene rubbers made with low boiling point solvents without the need or expense of finishing the polybutadiene and then grinding and redissolving it in styrene.
BRIEF DESCRIPTION OF THE DRAWING
The method and apparatus of the invention are further described and explained in relation to the following figures of the drawings in which:
FIG. 1 is a simplified flow diagram illustrating a preferred embodiment of the polybutadiene production portion of the invention;
FIG. 2 is a simplified flow diagram illustrating a preferred embodiment of the solvent exchange portion of the invention; and
FIG. 3 is a simplified flow diagram illustrating a preferred embodiment of the high impact polystyrene polymerization and finishing portion of the invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring to FIG. 1, which depicts the butadiene polymerization section of the invention, a hydrocarbon solvent is received from source 10, preheated in exchanger 12, and introduced into pumparound or recycle stream 14, which is charged to vessel 16 by pump 18. Preferred hydrocarbon solvents for use in the invention include low-boiling-point solvents having molecules containing from 4 to 6 carbon atoms. Particularly preferred solvents for use in the method of the invention include n-hexane and n-butane. Other low-boiling-point hydrocarbon solvents suitable for use in practicing the invention include, for example, cyclohexane, cyclopentane, and heptane.
Butadiene received from source 20 and minor effective amounts of tetrahydrofuran 22 and a gel inhibitor 24 such as 1, 2, butadiene, or another similarly effective inhibitor as known to those of ordinary skill in the art, are desirably injected into preheated solvent line 26 prior to introducing the preheated solvent into stream 14. A polymerization catalyst, most preferably a conventional n-butyl lithium catalyst is also charged to vessel 16 from source 28 through line 30.
Vessel 16 is preferably a stirred, jacketed reactor having temperature and pressure monitors 32, 34 and jacket water supply and return lines 36, 38, respectively. A preferred operating temperature for vessel 16 ranges from about 90° to about 120° C. and a preferred operating pressure range from about 150 to about 450 psig, depending on the polymerization solvent used. It will be appreciated by those of ordinary skill in the art, however, that the preferred operating temperatures and pressures for vessel 16 can vary within the scope of the invention according to factors such as the polymerization initiator utilized or the polymerization solvent selected.
Discharge line 40 from vessel 16 preferably functions as a plug flow reactor for the polymerization of the butadiene, and will preferably be of sufficient length and diameter to facilitate the production of from about 1 to about 15 weight percent, and most preferably about 12 weight percent, polybutadiene in the mixture. The reactor pressure is desirably controlled by control valve 42 in response to signals received from pressure monitor 34. According to a particularly preferred embodiment of the invention, a coupling agent and antioxidant are metered into line 40 from sources 44, 46, respectively by any conventional, commercially available means, and static mixers 48, 50 are provided to facilitate dispersal of those materials into the polybutadiene mixture.
Those of ordinary skill in the art will appreciate that the butadiene polymerization process as described above in relation to FIG. 1 does not differ materially from the solution polymerization processes practiced commercially by other manufacturers of polybutadiene rubbers. Many operational details are omitted because they are well known and described in the literature. Some polybutadiene manufacturers have disclosed particular methods for improving yields, reducing solvent requirements, and the like, by implementing other apparatus or procedures that may also fall within the scope of the present invention when combined with the other elements disclosed herein. None are known, however, to have disclosed an apparatus or method for diluting a reacted polybutadiene/solvent mixture with a monovinyl aromatic monomer such as styrene and thereafter exchanging the solvent by flashing it off through vacuum devolatilization to produce a feed stream for the polymerization of a rubber-modified vinyl aromatic polymer such as high impact polystyrene.
Referring to FIG. 2, which depicts the solvent exchange section of the invention, a vinyl aromatic monomer, most preferably styrene, is introduced into line 40 upstream from control valve 42, and is desirably dispersed throughout the rubber mixture by conventional static mixer 52. The diluted mixture is then preferably preheated in exchanger 54 and introduced into first devolatilizer 56 to flash off the hydrocarbon solvent. Devolatilizer 56 is a conventional vacuum devolatilization unit that is jacketed to permit the circulation of hot water 58 and is desirably operated at a pressure of about 140 mbar where the hydrocarbon solvent being flashed off has a boiling point ranging from about that of hexane (66° C.) to that of butane (61° C.). Devolatilizers are preferred for use in the invention to assist in removing the solvent. According to a particularly preferred embodiment of the invention, the partially devolatilized polymer stream 60 is moved by pump 61 from the bottom of devolatilizer 56 to be further heated in exchanger 62, and then introduced into a second devolatilizer 64 constructed and operated similarly to devolatilizer 56.
Overhead vapor streams 66, 68 containing solvent, unreacted butadiene and unreacted vinyl aromatic monomer from both devolatilizers are combined and directed to a conventional vapor recovery section 70 comprising conventional separation equipment (not shown) for separately recovering the hydrocarbon solvent and unreacted vinyl aromatic monomer. The solution discharged from the bottom of devolatilizer 64 preferably contains from about 5 to about 12 weight percent polybutadiene and is transferred by pump 72 to the styrene polymerization section of the invention, as depicted in FIG. 3.
The solvent exchange and recovery operations described herein are desirably controlled so as to prevent any significant carryover of butadiene into the styrene polymerization section due to its high potential for gelling. Solvent contamination of the styrene/polybutadiene stream is also desirably reduced to levels of less than about 1000 ppm, and most preferably less than about 100 ppm. Using a lighter solvent such as butane instead of hexane should facilitate separation of the solvent from styrene.
Referring to FIG. 3, the styrene polymerization section of the invention, this stage of the HIPS process can be operated much the same as a conventional HIPS manufacturing process, wherein a styrene monomer feedstock has had a premanufactured polybutadiene or SBR type rubber, which has been ground into small particles, dissolved in it. More specifically, the solution discharged from the bottom of devolatilizer 64, containing from about 5 to about 12 weight percent polybutadiene dissolved in styrene monomer, is pumped by pump 72 to the first HIPS reactor 80 which comprises a Pre-Inversion Reactor (PIR) as more fully described in the aforementioned incorporated patent U.S. Pat. No. 4,777,210. The PIR is primarily of the continuous-stirred tank reactor type.
The solution is reacted in the PIR 80 and the viscosity monitored by monitoring the amperage drawn by the stirrer motor on the reactor, until the viscosity reaches the point just prior to where the solution has reached the inversion point of the syrene/polystyrene/polybutadiene mixture. The inversion point is that point where the solution goes from a matrix of styrene/rubber with particles of polystyrene, to a solution where the matrix is polystyrene with particles of polystyrene/rubber dispersed therein.
As the solution is stirred and reacted until measuring the viscosity indicates that it is producing product near the inversion point in PIR 80, the solution is pumped from the PIR 80, via flowline 81, to the Post Inversion Reactor 82 which is also preferably of the Continuous Stirred Tank Reactor type. Phase inversion begins essentially immediately after the feed solution enters Reactor 82 and the feed solution has a sufficient residence time in Reactor 82 to substantially complete the phase inversion.
From the Post Inversion Reactor 82, the solution is pumped from product line 83 into a third reactor comprising a Plug Flow Reactor (PFR) 84 where the polymerization is substantially completed. The solution is flowed from the PFR into a heat-exchanger 85 where it is heated preparatory to being devolatilized in Devolatilizer 86. From the Devol 86 the product stream is passed to a pelletizer (not shown) where the product is formed into solid pellets for shipment.
Other alterations and modifications of the invention will likewise become apparent to those of ordinary skill in the art upon reading the present disclosure, and it is intended that the scope of the invention disclosed herein be limited only by the broadest interpretation of the appended claims to which the inventors are legally entitled. | A method and apparatus for use in making high impact polystyrene by polymerizing butadiene into polybutadiene, continuously exchanging styrene monomer for the solvent used to produce the polybutadiene, and polymerizing the resultant polybutadiene/styrene solution into high impact polystyrene. Apparatus is disclosed that includes butadiene and solvent preparation means, additive metering means, butadiene polymerization means, solvent exchange means, solvent recovery means and styrene polymerization means. | 2 |
[0001] This application claims priority under 35 U.S.C. 119 from Provisional Application Serial No. 60/268,082 filed Feb. 13, 2001.
FIELD OF THE INVENTION
[0002] The present invention relates generally to the field of concrete manufacture and more particularly to the field of recovery methods for recycling hydrated cement from returned concrete.
BACKGROUND OF THE INVENTION
[0003] Over the past decade, governments and environmental groups have increased pressure on the ready-mix industry to reduce waste discharge. The high-pH, toxic, alkaline run-off caused by waste cement is now classified as a hazardous waste in some parts of the world and it is expected that the U.S. and Canada will soon mandate zero-discharge regulations for its ready-mix industry.
[0004] The problem is caused by hydrated cement, which contains Calcium Hydroxide—(Ca(OH) 2 ), the highly alkaline substance that acts as the binary agent in concrete. When Ca(OH) 2 is released into the environment, it can be deadly to fish and wildlife and can potentially poison other public waterways. Ca(OH) 2 created by concrete production routinely exceeds the maximum allowed discharge pH levels for most civic process discharge permits.
[0005] Conversely, if recycled into fresh concrete without treatment, Ca(OH) 2 can cause poor slump control, reduced strength and unpredictable finishing characteristics. Once cement is exposed to water and hydration begins, it must continue until the process is exhausted or suspended. The longer the hydration period, the greater amount of Ca(OH) 2 produced.
[0006] In recent years, chemical admixture producers have developed hydration stabilization admixtures (HSA), which have provided the solution to the hydration problem of the cement. Since it is now possible to suspend hydration for a controlled period of time (stabilize), partially hydrated cement can be recycled before it entirely converts to calcium hydroxide through hydration. This also means that a portion of the cementitious value can be saved for later use.
[0007] Conventionally when a concrete mixer truck returns to the plant after delivering a load, there is almost always unused concrete and/or residue accumulated on the inside of the truck drum and chutes. The system delivers chemically treated system-water to the truck drum to suspend hydration and dilute and rinse the drum contents into the close-circuit reclamation and recycling system.
[0008] The process of hydration stabilization can be found in a technical document named “A Novel Method Of Recycling Concrete Using Extended Life Admixtures.” Co-authored by Lawrence R. Roberts of W. R. Grace (Conn.) and Seiji Nakamura of K.K. Denka Japan, which was released at the European Ready-Mix Association congress in 1998, the disclosure of which is incorporated herein by reference.
[0009] The term system-water may, throughout this document, also be referred to as wash-water, washout fluid, slurry and batch slurry. It should also be noted, that throughout the course of this process description, when the system transfers slurry from the recovery tank to the secondary tank, the nomenclature used to describe the slurry will change from “system-water” to “batch slurry”. This is intended to clearly define the difference in the intended purpose of the slurry in each part of the process. The sand and gravel are classified out of the drum contents using, for example, a spiral-classifier re-claimer, while the cement and very fine sand report to the primary tank with the circulating system-water.
SUMMARY OF THE INVENTION
[0010] It is one object of the present invention to provide an improved method for re-claiming and recycling cement into concrete production.
[0011] According to the invention, there is provided a method of recycling waste unset concrete materials containing water, aggregates and partially hydrated cement, the method comprising:
[0012] providing a recovery tank;
[0013] introducing into the recovery tank water and hydration stabilization chemicals to provide a washout fluid including same;
[0014] providing a plurality of transit mixer drums, each containing a quantity of waste concrete;
[0015] for each transit mixer drum;
[0016] transferring from the recovery tank a quantity of the washout fluid from the recovery tank into each transit mixer drum;
[0017] mixing the waste concrete in the transit mixer drum and the washout fluid, thereby forming an aggregate slurry;
[0018] transferring the aggregate slurry into an aggregate re-claimer so as to separate the aggregate slurry into aggregates and slurry;
[0019] and transferring the slurry to the recovery tank;
[0020] providing a slurry supply system for supplying the batch slurry to a concrete batching plant for use of the batch slurry in mixing with aggregates and cement to form fresh concrete in the batching plant;
[0021] and transferring the batch slurry from the recovery tank to the slurry supply system for use of the batch slurry.
[0022] According to one important feature of the invention, the slurry is transferred from the recovery tank to the slurry supply system for use of the slurry as the batch slurry at a predetermined constant density. This allows the batcher to receive batch slurry at a constant condition ensuring that it can be utilized in predetermined batch mixes utilizing the known and constant parameters of the slurry
[0023] Preferably the system-water from the recovery tank is mixed with dilution water to reduce a density of the system-water from the recovery tank to the predetermined constant density.
[0024] In one arrangement, after dilution the diluted system-water is stored in a secondary tank from which smaller individual batches are drawn as batch slurry for the batch slurry supply system.
[0025] Preferably the system-water from the recovery tank is mixed with dilution water in a transfer duct as it is being transferred between the recovery tank and the secondary tank.
[0026] In another arrangement, the system-water from the recovery tank is mixed with dilution water in a transfer duct as it is being transferred to the slurry supply system so that it is stored at an elevated density and diluted only when required at the batching plant.
[0027] Preferably the density of the slurry is measured while it is in the duct and a rate of supply of the dilution water is increased until the required density is reached whereupon the rate of supply of dilution water is maintained constant. In this arrangement, information can be stored defining the rate of supply for subsequent transfer of system-water so that the required adjustment can be achieved more quickly.
[0028] In order to transfer only batch slurry at the required density, the batch slurry is returned to the recovery tank until the required density is reached.
[0029] In accordance with another important feature of the invention, the water and hydration stabilization chemicals are introduced simultaneously into the recovery tank at a predetermined calculated ratio.
[0030] Preferably the predetermined ratio is determined based upon a target density for the system-water in the recovery tank and preferably all the water and hydration stabilization chemicals are introduced at that set ratio while the density is at or below the target density. This allows a simple calculation and adjustment and control of the supply in that all materials are supplied at that same ratio which is determined by the target or intended density value even though the density may to reach that target until a number of recoveries have been made, following which the density is controlled by addition of further water and chemicals at the same ratio. For example, in order to keep cement hydration suspended for a period of 48 to 72 hours at a target density of 1.15 g/cm 3 (20% solids by mass), HSA will need to be added to the water at a ratio of 0.002:1 or 2.00 liters of HSA for each 1000 liters of water. If, alternatively, the density was 1.07 g/cm 3 (10% solids by mass), the amount of HSA would change to 0.0015:1 or 1.5 liters of HSA for each 1000 liters of water. These ratios will be scaled in accordance with temperature variations in the system-water.
[0031] In order to maintain that target density, the density of the system-water is repeatedly measured and additional water and chemicals at the same set ratio are added when the density exceeds the target density to dilute the system-water to said target density.
[0032] The ratio may be calculated including as a calculation factor the temperature of the system-water in the recovery tank and heating and/or cooling may be applied to the system-water to maintain the system-water at said temperature.
[0033] In the event that the recovery tank is filled to capacity and the target density is exceeded to an over density, additional chemicals are added without additional water to provide a quantity of chemicals sufficient for said over density.
[0034] In accordance with another important feature of the invention, there is provided a sleep mode in which the slurry is to be left in storage for a period of time greater than a working period, in which mode additional chemicals are added without additional water at an amount dependent upon the time period beyond the working period. For example, if the density rises to 1.20 g/cm 3 (14% solids by mass), chemical will be added according to the density based on the assumption that the tank is full and the chemical must be added in ratio to that full volume. Up to and including a density of 1.30 g/cm 3 (35% solids by mass) the system will add chemical at incremental intervals of one unit of specific gravity across the entire volume of the recovery tank.
[0035] The slurry supply system may include a batch tank dimensioned to receive and store a batch of the batch slurry substantially equal to or greater than a required batch for the batch plant.
[0036] It is advantageous if the batch tank has a discharge for supply to the batch plant which discharges the slurry at a rate greater than a rate of supply thereto so that the batch can be discharged rapidly into the batch plant for use while the batch tank can be re-filled more slowly using the transfer pump from the secondary tank to the batch tank.
[0037] Preferably the secondary tank is dimensioned to hold a quantity of the batch slurry equal to or greater than a series of batches of the batch tank for use of the batch tank repeatedly during a work period, for example one shift or one day, and wherein the secondary tank is filled with the required amount of diluted slurry from the recovery tank for that period. For example, if the batcher requires 125 liters per cubic meter of concrete, and he must batch 300 cubic meters over the course of a work period, then he will need to transfer 37,500 liters of batch slurry to the secondary tank during the work period to fulfill that requirement.
[0038] Preferably the batch slurry is stored at a temperature lower than a required temperature for the concrete batching plant and is mixed with hot water to raise the temperature to the required temperature at or prior to the batching plant. In this arrangement the batch slurry can be diluted with hot water to effect heating to the required temperature and to effect reduction in density to the required density.
BRIEF DESCRIPTION OF THE DRAWINGS
[0039] Two embodiment of the invention will now be described in conjunction with the accompanying drawings in which:
[0040] [0040]FIG. 1 is a schematic diagram of a first embodiment of the concrete recovery system.
[0041] [0041]FIG. 2 is a schematic diagram of a second embodiment of the concrete recovery system.
[0042] [0042]FIG. 3 is a side elevational view of the concrete recovery system showing the arrangement of the components.
[0043] [0043]FIG. 4 is a top plan view of the concrete recovery system showing the arrangement of the components.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0044] The embodiments shown in FIGS. 1 and 2 includes a concrete recovery system 1 comprises: a conventional flume 8 , a conventional aggregate re-claimer 10 , a recovery tank 12 , a secondary tank 11 , a batch tank 14 , a control unit 16 including a dilution management assembly 22 , a chemical supply 18 and a batch water supply 38 .
[0045] The aggregate re-claimer 10 separates waste concrete mixture into aggregate material and slurry. In some embodiments, the aggregate re-claimer 10 may be, for example, a gravity screw or trommel re-claimer with a de-watering weir and screw and may include the rinse flume 8 , as described below. Other suitable arrangements may also be used, according to the manner in which the user wishes to recover aggregates. In some embodiments, the aggregate re-claimer 10 recovers aggregate to 150 microns or #100 mesh in size or smaller.
[0046] The recovery tank 12 holds system-water and is connected to the aggregate re-claimer 10 for supplying washing fluid for removing waste concrete, as described below. As described below, at the start of each cycle, the recovery tank holds water containing a hydration stabilization admixture (HSA). Initially, this mixture circulates through the aggregate re-claimer 10 , acting as washout water, as described below. As trucks wash out, a density meter 20 and a temperature monitor 20 B in a discharge line 20 A regularly monitors the density of the resulting system-water circulating from the tank 12 through the discharge pump 20 C and an irrigation valve 20 D. Over the course of the day, as the density of the system-water rises, the control unit 16 adds more fresh water from supply 38 and HSA from supply 18 in order to maintain a target slurry density, as described below. In some embodiments, the solids in the system-water are kept in suspension in the recovery tank 12 with an impeller agitator 24 .
[0047] The secondary tank 14 stores the batch slurry for use in the preparation of concrete. Specifically, system-water accumulated in the recovery tank 12 is pump-transferred to the secondary tank 11 for temporary storage until it can be re-used as batch slurry for mixing water in fresh concrete batches. In use, the batch slurry in the secondary tank 11 is transferred to batch tank 14 at the batch plant at the request of the batcher or system. In some embodiments, the recovery tank and the secondary tank 11 may each include an agitator 26 , for example, an impeller agitator for keeping the slurry in suspension. In the first embodiment described herein, the batch slurry in the secondary tank 14 is transferred from the recovery tank at the same target density where it is stored at an elevated density of between 1.07 and 1.30 g/cm 3 .
[0048] To effect transfer, the irrigation valve 20 D and the giraffe valve 20 E are closed and a transfer valve 20 F is opened simply acting to transfer all materials pumped by the pump 20 C into the secondary tank 11 at the same density as the target density in the recovery tank.
[0049] When required at the batching plant, the slurry is pumped from the secondary tank 11 through the dilution management assembly 22 described below. For example, the density required to batch maybe set at a lower density such as 1.07 g/cm 3 , although this may be set at different values depending upon the batcher's requirements, which will require a fresh water to slurry water blend of 1:1 if the reservoir density is 1.15 g/cm 3 to as much as 4:1 if the reservoir density is 1.30 g/cm 3 , as described below.
[0050] In the embodiment of FIG. 1, the control unit 16 monitors and maintains the density of the system-water in the recovery tank 12 and the batch-slurry in the secondary tank 11 and delivers the batch slurry at a predetermined density to the batch plant, as described below. A Coriolis density meter 20 is installed on the slurry line to monitor the density of the batch slurry in real time in the re-circulation loop, as described below. As will be appreciated by one knowledgeable in the art, other suitable density meters known in the art may also be used. The density meter 20 feeds back to a PLC control system that will monitor and adjust the system settings to allow proper blending, as described below. An Operator Control Panel is installed at the batch station to allow the batcher to monitor the system and make periodic adjustments as may be required to reflect the changing needs of the user.
[0051] The dilution management assembly 22 in some embodiments is placed as close to the batch plant as possible. In one embodiment, the assembly sits atop a metal platform 50 that is approximately 10 to 12 feet in length and 4 to 6 feet in width. As shown in FIG. 1, the secondary tank 11 is connected to a batch slurry feed line 27 and a circulation loop 34 . There is a “Y” valve 25 that allows the slurry feed line 27 and fresh water feed line 23 to flow into a common line 26 , as described below. The common line 26 following the “Y” valve 25 is in one embodiment approximately 5 feet in length to allow the diluted batch slurry to settle from a turbulent flow to a laminar flow. The common line 26 is connected to the density meter 28 , as shown in FIG. 2. Downstream pipe 29 exits the density meter 20 and is connected via pipe 27 to return valve 32 that leads to the secondary tank 11 . The downstream pipe 29 is connected to a discharge valve 30 that allows the slurry to report to the batch water weigh hopper 14 . In other embodiments, the batch slurry may be introduced into the batch process using a flow meter rather than a weigh hopper. It is of note that when the discharge valve 30 is open, the return valve 32 at the head of the return line to the secondary tank 11 closes. These two valves operate opposite one another, so that the return loop and the batch weigh hopper delivery line will remain independent, allowing the proper dilution to be established into the lop before the valve 30 is opened to allow the properly diluted slurry to flow to the batch tank 14 .
[0052] In use of the first embodiment, before the commencement of operations on any given day or as required by the producer, the recovery tank 12 has added thereto an initial quantity of water and a corresponding amount of HSA. The principle of chemically stabilizing cement is based on the use of a carboxylic acid to suppress hydration activity for a defined period of time. This is accomplished by adding a specific quantity of HSA to a known quantity of water in which cement particles will be suspended for an established period of time. The purpose of the specific quantity of HSA is to stabilize the cement hydration for a finite period of time. In most cases, the cement will require stabilization for 12-24 hours. Further detail on the process of hydration stabilization can be found in the above mentioned technical document named “A Novel Method Of Recycling Concrete Using Extended Life Admixtures.” Co-authored by Lawrence R. Roberts of W. R. Grace (Conn.) and Seiji Nakamura of K.K. Denka Japan, which was released at the European Ready-Mix Association congress in 1998. A transit mixer 22 backs to the rinse flume of the aggregate re-claimer 10 to discharge waste concrete remaining in the mixer drum of the transit mixer 22 . The operator depresses a water delivery button at the aggregate re-claimer 10 that causes water from the recovery tank 12 to be pumped via, for example, a giraffe pipe into the transit mixer drum. The water and waste concrete is then mixed at high speed for a period of time, for example, two minutes, thereby forming an aggregate slurry. The aggregate slurry is then discharged into the aggregate re-claimer 10 .
[0053] The aggregate re-claimer 10 removes all aggregate material larger than 150 microns from the washout, for example, by means of a gravity de-watering screw or trommel re-claimer, and discharges the aggregate into aggregate bunkers for eventual return to stockpile. Thus, reclaimed aggregates can be screened to their original classifications and returned to stockpile at full value. The aggregate re-claimer 12 is able to recover fines down to at least 150 microns or smaller, leaving a slurry with a cementitious to non-cementitious ratio of fines ranging from 70:30 to 90:10.
[0054] It is desirable to remove as much of the non-cementitious fines from the aggregate slurry as possible. Reduction of coarse and non-cementitious fines reduces abrasion wear, extending the life of the components of the concrete recovery system 1 and allows for more efficient use of chemical stabilizer and greater system capacity for storage of more valuable cement and fly ash.
[0055] The system water/slurry is then discharged to the recovery tank 12 until needed for subsequent washouts. A density meter 20 regularly reports the density of the system-water in the recovery tank 12 to the control unit 16 . Based on the user's system settings, the control unit 16 may periodically add more water and/or HSA as the density of the system-water rises.
[0056] Thus, over the course of the production day, the density meter monitors the rise of solids in the slurry. If the percentage of solids rises above a preset limit, an additional draft of water will be pumped into the tank with a corresponding amount of HSA. As discussed above, the goal is to keep the density of the system-water at a target limit.
[0057] If high volumes of washout cause the system-water solids to continue to rise after the design volume capacity limit of the system has been reached, further HSA will be added according to the solids increase, but not water. This guarantees that the cement in the slurry will remain uniformly stabilized for the time that it is required to remain in storage.
[0058] When the production day is complete, the control unit 16 automatically transfers the slurry from the recovery tank 12 to the secondary tank 14 . Alternatively, the user may choose a specific time or set of conditions when the control unit 16 will automatically transfer slurry from the recovery tank 12 to the secondary tank 14 . When the batcher requests batch water for process mixing, it is drawn from the batch tank 14 instead of from a fresh water source. When the batcher asks the system to deliver slurry to the batch tank, water weigh hopper or through a flow meter to the batch process, the system 1 immediately begins a dilution cycle to reduce the density from the higher values in the secondary tank 11 to the lower values required at the batch plant. This is initiated by a real time density measurement to determine if the density is above or below the target value required, as described below. If the density exceeds the target value allowed by the batching process, the system 1 will instruct a fresh water valve 40 to open to begin diluting the batch slurry. As the valve 40 opens, the slurry line will begin to accept fresh water until the density reaches the target batch density, at which point the discharge valve 30 will open and the diluted batch slurry will be discharged to the batch tank 14 , water weigh hopper or flow meter. When the appropriate amount of batch slurry has been delivered, the discharge valve 30 will close and the fresh water supply will be terminated. The batch slurry will then continue to circulate until the batcher calls for more dilute slurry to batch. It is of note that the slurry water is delivered to the batch plant at a controlled predetermined density, preset by the operator and programmed into the control unit 16 . Solids in the batch slurry are compensated for, by adjusting mix designs to allow for reduction of fresh ingredients and addition of slurry solids.
[0059] It is of note that the slurry dilution cycle may be initiated by the batcher or by a tank level indicator in a batch tank 14 that asks the system 1 to automatically refill the batch tank 14 if it drops below a certain volume level. However that supply is always at the predetermined density due to the controlled inline dilution from the higher density of the slurry stored in the secondary tank 11 .
[0060] The actual step by step procedure of diluting the stored batch slurry to batch density is as follows. When the batcher starts the slurry re-circulation loop, a re-circulating valve 44 is open and the meter valve 25 is closed, so that the batch slurry flows along a circulation loop 34 back to the tank 11 . Next, the system 1 closes re-circulating valve 44 and discharge valve 30 and opens meter valve 25 and return valve 32 . As a result of this arrangement, the batch slurry will pass through the dilution management assembly 22 for a period of time sufficient to determine the density and temperature of the batch slurry. Once density and temperature have been established, the system 1 will update agitator speed and sets the slurry transfer pump speed to reflect the rate that the undiluted slurry is delivered to the dilution management assembly 22 . This rate is consistent with the ratio of blending that will be required to reduce the batch slurry from its storage density to the batch density. Once agitator and pump speeds have been set, the system 1 closes the meter valve 25 and the return valve 32 and opens the re-circulating valve 44 . As a result of this arrangement, the batch slurry returns to re-circulating loop 34 and the system 1 awaits the next command from the batcher. When the batcher or the system 1 calls for batch slurry to be delivered to the batch tank 14 or flow meter, the system 1 closes the circulating valve 44 and the discharge valve 30 and opens meter valve 25 and return valve 32 . The variable frequency drive on the batch-slurry transfer pump motor then increases or decreases pump speed to control the rate of slurry delivery to the dilution management assembly 22 . For example, when using a peristaltic (hose) pump as a batch slurry transfer pump, the fresh water to batch slurry water ratio is determined by a system preset. For example, if the stored batch slurry in the tank has a density of 1.15, the system will require approximately a 1:1 ratio of fresh water to batch slurry water to dilute the batch slurry to 1.07. Therefore, if the batch slurry transfer pump is set to deliver 100 gallons per minute to the batch tank 14 , the fresh water valve 40 will also deliver 100 gallons per minute, providing a total flow of 200 gallons per minute of batch slurry diluted to 1.07. In a different scenario, where the stored batch slurry in the secondary tank 11 is at a density of 1.30, the fresh water to batch slurry ratio will be 4:1, in which case the batch slurry transfer pump will be set to deliver 40 gallons per minute to the dilution management assembly 22 , while the fresh water valve 40 will deliver 160 gallons per minute to the dilution management assembly. This will also provide a total flow of 200 gallons per minute of batch slurry diluted to 1.07. It is of note that in some embodiments, the batch slurry transfer pump will have not less than four possible speeds of slurry delivery to accommodate four different batch slurry densities. Small variations in batch slurry density between the set points will be compensated by real time adjustments in the fresh water flow rate. As the batch slurry and fresh water converge and flow into the density meter 20 , the density of the diluted batch slurry is monitored and reported back to the system 1 . If the density is above or below the batch target density, the fresh water valve 40 will open or close to bring the density into a target range, typically between 1.069 g/cm 3 and 1.075 g/cm 3 if the target density is 1.07 g/cm 3 . Once the batch target density has been reached, the system 1 closes return valve 32 and opens discharge valve 30 . This allows the batch slurry to report to the batch tank 14 . The flow will continue until the batch tank 14 records a full reading and instructs the system 1 to return to re-circulation, or until the batcher has received enough diluted batch slurry in the weigh batch hopper 14 and instructs the system 1 to stop delivering batch slurry. Once the system has stopped delivery of batch slurry to the weigh batch hopper 14 , the settings of the dilution management system 22 will be recorded in a PID loop that will instruct the system to return to its last known delivery settings the next time batch slurry is called to batch. This will reduce the time required to find the exact batch target density to a few seconds rather than 15 to 30 seconds.
[0061] If the system 1 requires hot water to compensate for cold weather aggregate temperatures, the dilution management system can use hot water as its fresh water feed source, eliminating the need to blend several water sources to arrive at a suitably blended batch slurry temperature and density, or can use a hot water heat source as shown in FIG. 1.
[0062] The primary function of the concrete recovery system 1 is to safely and efficiently recycle cementitious slurry water. In order to accomplish this, it is necessary to develop a consistent and carefully controlled method of incorporating slurry into the batching process. The key to accomplishing this is to maintain a constant regular density for all recycled slurry water. The in-line dilution and mixing process dilutes a stream of cementitious slurry with fresh water in flow, arriving at a target density that will be both consistent and reliable. This constant supply of slurry at a stable target density allows the ready-mix producer to use the slurry water as mixing water for manufacturing fresh concrete. Furthermore, the stability of the slurry density acts as a quality control constant, providing consistently similar performance characteristics of the fresh and hardened concrete. Maintaining regular density allows the producer to develop mix designs for use of the slurry that are constant and reliable in both placing characteristics and final strengths. It also allows the producer to balance the amount of slurry accumulated over a given day with the amount distributed over the following day's production. This balancing of intake and outflow will assists in guaranteeing quality control. By eliminating the need to calculate the blending ratios, the system is as close to fail safe as can be expected. In this regard, the discharge valve 30 must remain closed until the density meter 20 reads that the diluted batch slurry density has reached the target range and is ready to be released. From a batcher's standpoint, the system frees him from having to modify mix designs to compensate for fluctuating densities, and practically eliminates the risk of liability associated with concrete failures due to error in compensatory calculations by the batcher.
[0063] Thus, the concrete recovery system is an aggregate re-claimer and slurry recovery system that operates on a closed circuit, zero-discharge principle, and can be implemented as a parallel system with any ready-mix batch plant. The system reclaims aggregates for re-use and recovers cementitious slurry for re-use as process mixing water, as described below. The system combines density management with chemical hydration stabilization in a self-monitoring and self-regulating storage and transfer environment. The fundamental goal of the system is to return the batch slurry to batch at a controlled density, allowing the cementitious solids in the batch slurry to be recovered as replacement material for fresh fly ash or cement.
[0064] In practical terms, when the batcher calls for batch slurry, it is delivered to the batch plant at the preset density. This density will correlate with the slurry-based mix design written into the batch computer. The underlying principle is to maintain exactly the same batching procedure as would be followed under normal circumstances. The only difference is that part of the cementitious material is supplied with the slurry, allowing the operator to reduce the cement and/or fly ash called for in the mix design.
[0065] For example, a normal Portland 25 MPa mix design calling for:
[0066] 215 Kg cement
[0067] 70 Kg fly ash
[0068] 105 Kg fresh water
[0069] Could be replaced with a mix design calling for:
[0070] 210 Kg cement
[0071] 65 Kg fly ash
[0072] 116 Kg slurry at a density of 1.07
[0073] In another configuration for example, in which the concrete producer chooses to simply dispose of the cementitious slurry solids in the fresh concrete batches, he may choose not to modify the mix designs, but rather let the slurry solids be added to the fresh mix in addition to the normal distribution of the constituent ingredients and allow the final strength to be over-designed and the benefit to carry forward to the concrete purchaser.
[0074] In all other respects, the mix design would be identical to a normal production design, and since the cement slurry is stabilized, it will not affect other admixture relationships in the fresh batch such as air entrainment.
[0075] Turning now to the second embodiment shown in FIG. 2, this is modified from the first embodiment by a number of features, the primary one of which is that the control of the dilution of the batch slurry to the required density occurs between the primary tank and the secondary tank so that the required amount of batch slurry for a period of use, typically one day or one production cycle, is stored in the secondary tank at the required density and can be supplied at that density on demand to the batching system. Thus an additional fresh water line 38 A from the supply 38 is connected through a valve 38 B to the output from the pump 20 A for mixing with the slurry from the tank 12 . The return loop 34 A for establishing the required dilution is formed through the irrigation valve 20 D following which the valve 20 D is closed and the valve 30 opened to transfer the accurately diluted slurry to the secondary tank 11 . Transfer from the tank 11 to the batch tank 14 is effected through valves 53 and 51 and pump 52 .
[0076] The following is a detailed description of the second embodiment, which may repeat some aspects which are common to both embodiments.
[0077] The trucks will receive system-water for drum rinsing through giraffe transfer pipes 20 F and valve 20 E at each truck station. They will discharge the waste concrete mixture or aggregate and slurry into an intake flume with internal rinse irrigation. The flume will provide for quick discharge of aggregate and slurry and controlled feed into the re-claimer. The coarse aggregate is classified out of the drum contents by means of a 36″×25′ spiral-classifier and discharged into a storage bunker, while the cement, low-density fines and water flow into the primary tank in slurry form.
[0078] The principal storage and transfer component of the system are: two API 650 storage tanks 12 and 11 mounted on a rigid skid-frame 50 located at the washout transfer station and one (1) batch tank 14 located at the plant. The system is delivered as a complete unit ready for use, with operating components fixed to the skid-frame. It may be installed quickly and efficiently without disrupting plant operations.
[0079] The API 650 tank capacities can be expanded with flanged sections to extend nominal tank height from a base design of 9′ 6″ up to 14′ 6″ or even as high as 19′ 2″. The tanks 11 and 12 are fitted with agitators 26 to maintain controlled homogeneity of the contents. The three standard tanks are designated as follows:
[0080] The recovery tank 12 holds a maximum 34,500-liter volume of system-water containing a hydration stabilization admixture (HSA). This system-water circulates through the washout transfer station and re-claimer providing rinse water for the trucks 22 and irrigation water for the re-claimer 10 .
[0081] The secondary tank 11 holds a maximum 55,250-liter volume of batch slurry in temporary storage until it can be re-used as mixing water in fresh concrete production.
[0082] The 1,720-liter batch tank 14 automatically receives batch slurry from the secondary tank to maintain a just-in-time volume of batch slurry for use in fresh concrete mixes as required by the batcher. The recycle water port on the batch computer actuates the discharge valve on the batch tank.
[0083] The process equipment and system instrumentation is mounted on the skid and/or affixed to the tanks as required. This includes the following:
[0084] All tanks are fitted with agitators 26 and tank baffles to keep solids in proper suspension. The agitators are hydrofoil-impellers that provide maximum homogeneity with minimum shear abrasion.
[0085] The primary pump 20 C delivers system-water to the truck drums 22 for rinsing and irrigates the re-claimer 10 and flume 8 to wash the waste concrete mixture into the system. The primary pump 20 C transfers system-water from the recovery tank 12 to the secondary tank 11 .
[0086] The secondary pump 52 delivers batch-slurry from the secondary storage tank to the batch tank at the plant for use as mixing water in fresh concrete.
[0087] An in-flow density meter 20 monitors system-water/batch slurry density and temperature. The information is used to control system-water/batch slurry density and temperature management and the transfer-dilution process.
[0088] A service 38 for fresh water addition is mounted to the skid-frame 50 consisting of a flow meter and automated control valve.
[0089] All piping and fittings are schedule 40 with long radius elbows to reduce abrasion. All process control valves are high quality, 150-p.s.i.-rated pneumatic pinch valves with replaceable rubber sleeves.
[0090] All tank volume levels and high-low signals are monitored and reported to the system controls by an ultrasonic level sensor and transmitter 60 . This gives the batcher a visual graphic and corresponding numeric value at the batch plant indicating the volume and level in each tank and triggers automated system activities.
[0091] The recovery tank monitors temperature at the density meter 20 , while the secondary tank is fitted with a thermal sensor 61 to monitor batch slurry temperature. These sensors can be used to interface with a heat exchanger or other variety of heating or cooling system (not shown).
[0092] A chemical addition system 18 automatically injects HSA into the system-water and is designed to feed chemical into both tanks as the system demands.
[0093] The dilution management system uses fresh or process water to dilute the recovery tank system-water to a constant density in transfer to the secondary tank, thereby guaranteeing a stable supply of batch slurry in the secondary tank at the density required to batch without manual calculation or risk of error.
[0094] The system management controls package ties the process equipment and controls into an integrated automation system. The system monitors, controls and maintains the system-water/batch slurry in storage and delivers it at a predetermined density to the batch plant.
[0095] An operator control panel (OCP) 16 is installed at the batch station to allow the batcher and quality control personnel to monitor the system and make periodic adjustments as may be required to reflect the changing needs of the producer.
[0096] When batching with batch slurry, the goal of the system is to provide the batcher with a stable supply of batch slurry at a constant density and also a constant temperature as required by the producer. This allows the batcher to use most existing batch computers to adjust or modify the final batch outcome.
[0097] If the user wishes to increase secondary storage density and dilute the slurry in the weigh hopper, the batch computer can be preset to add make-up water to a draft of recycled water to reduce density at the weigh hopper. This method expands the storage capacity of the system by allowing the secondary tank to store more slurry solids.
[0098] For example, if the storage density in the secondary tank and transfer circuit were set at 1.10 g/cm 3 , the batch computer could be set to automatically add make-up water to the slurry in the weigh hopper to reduce its density to 1.07 g/cm 3 by splitting the feed of slurry in ratio to fresh water at 1:0.6 or 60% slurry and 40% fresh water.
[0099] In winter batch-slurry can be stored at a relatively high density and at low temperature and diluted with hot water in the batch weigh hopper. This can be used to elevate batch-slurry to high temperature seconds prior to delivery, allowing heating of the slurry without propagating hydration across the stored volume in the secondary tank or allowing high-temperature initiated hydration to continue long enough to have any noticeable effect on the fresh concrete. The low temperature storage reduces the amount of chemicals required as hydration is temperature dependent. In the alternative, the mixing with hot water can be combined with the dilution step.
[0100] Each washout station is fitted with a 3″-diameter, giraffe-style overhead water-transfer pipe to deliver system water to the mixer drum. Each giraffe assembly is fitted with a user switch box with two (2) safety designed, all-weather push buttons, an open/close pinch valve and a flow meter. The start buttons will be clearly marked FULL RINSE and CHUTE RINSE.
[0101] The wash stations are positioned along a common collection flume into which the waste concrete mixture is discharged. A fresh-water hose will be mounted at each giraffe to facilitate manual truck chute rinsing. HSA will be injected into this rinse hose to maintain overall chemical balance during un-metered additions of rinse water (i.e. rinsing chutes and truck components).
[0102] Depressing the Full Rinse button will initiate delivery of a draft of system-water from the recovery tank to the truck drum. The draft quantity is user-defined (nominal 1000 liters). The chemical present in the slurry will coat the truck drum, aiding resistance to build-up of waste concrete. System-water will dilute the waste concrete mixture, making it flow-able and easily discharged. The end of the drum transfer cycle will initiate an irrigation cycle. Irrigation cycle time is user-defined (nominal 16 minutes). System-water conditions will be monitored during the irrigation cycle allowing system settings to be updated. If a full rinse cycle is in progress when a new driver depresses the Full Rinse button at his particular station, the system will restart the cycle.
[0103] Depressing the Chute Rinse button will initiate an irrigation cycle without a drum transfer by controlling the valves 20 D and 20 E.
[0104] Irrigation cycle time is user-defined (nominal 3 minutes). A rinse hose will provide chemically treated fresh/process water to rinse chute washout into the re-claimer. System-water conditions will be monitored during the irrigation cycle, allowing system settings to be updated. If a full rinse cycle is in progress when a new driver depresses the Chute Rinse button, the system will restart the cycle.
[0105] As multiple-serial transfer valves open or close, line pressure will rise and fall. The system senses the pressure change and adjusts the primary pump 20 C speed and flow rate to maintain a constant transfer flow rate regardless of the number of open valves. This will guarantee constant transfer times. The Full Rinse button starts the primary pump, opens the giraffe valve and delivers 1000 liters of system-water to the truck drum. When the drum transfer flow meter registers the complete transfer of system-water, the giraffe valve will close and the irrigation valve for the re-claimer will open. The re-claimer begins operation when irrigation valve opens. The irrigation system runs on a timer for 16 minutes and then automatically shut down the primary pump and re-claimer when the cycle is complete.
[0106] The Chute Rinse button starts the primary pump 20 C and the re-claimer without transferring system-water to the truck drum. The Chute Rinse button initiates a 3-minute rinse cycle through the re-claimer irrigation system. The end of the rinse cycle will cause the re-claimer and pump to shut down.
[0107] The operation of the re-claimer and flume will always be in conjunction with irrigation flow provided by the primary pump. Flow will be divided amongst the flume and re-claimer at a nominal flow rate of 600 liters per minute.
[0108] For example, a spiral-classifier, which employs a rising current classifier provides for efficient removal of low-density cementitious and sand fines while allowing heavier aggregate to sink to where the spiral can remove it from the re-claimer. A wash back channel in the spiral-classifier provides further irrigation by rinsing the spiral channel to keep it clear of accumulated fines.
[0109] The intake flume is fed with system water through rinse piping that will flush the waste concrete mixture into the re-claimer. The primary pump feeds the flume to maintain material recovery and separation at optimum efficiency.
[0110] The recovery tank has three principal functions. They are:
[0111] a reservoir for system-water used to irrigate on the re-claimer and provide rinse water for the trucks;
[0112] collection and storage vessel for cementitious and sand fines collected in the washout process; and,
[0113] the point of chemical stabilization for incoming cementitious material.
[0114] The recovery tank has a nominal volume of 34,500 liters or 9,100 U.S. gallons. It is fitted with a ULI and an in-flow density meter in its irrigation piping.
[0115] The recovery tank and re-claimer circuit have three possible operating modes. The parameters are user specified to reflect the needs of the producer. The modes are:
[0116] Target-Density Mode (TDM)—In TDM, the nominal density of the system-water ranges between 1.00 to 1.15 g/cm 3 ., and the system strives to maintain minimum volume at a constant density near the high end of that range. As solids enter after the high end of the range has been reached, dilution water and hydration stabilization admixture will be added to the tank at the pre-calculated ratio determined by the target density and the temperature to reduce the system-water density below the high end of the range and maintain the proper chemical/water ratio.
[0117] High-Density Mode (HDM)—In HDM, the nominal density of the system-water may rise as high as 1.30 g/cm 3 In HDM, the system disallows addition of fresh dilution water, but allows addition of HSA in proportion to temperature and density. Solids continue to be accepted by the system during HDM, but the system requests the batcher to transfer system-water to the secondary tank to allow return to TDM.
[0118] Sleep Mode (SM)—SM can be initiated by the batcher or automatically at a preset time. SM will start a system clock to monitor the age and temperature of the slurry with user-defined, periodic 3-minute irrigation cycles and timed system commands. The primary function of SM is age monitoring and HSA addition, which is tied to temperature changes in the system-water and batch slurry or a preset elapsed time limit on the system clock. If sleep mode continues unbroken for the length of the preset timed-cycle, the system will add chemical according to the volume, temperature and density of the system-water and/or batch slurry, and return the preset timer to zero to begin a new cycle. In SM, a gate valve 53 between the secondary tank and the batch tank will close, preventing slurry solids form migrating into the secondary transfer pump casing and also acting as a security precaution against spillage in the event of a seismic event. Furthermore, the isolation of the secondary transfer line from the secondary tank will allow the secondary transfer line to be purged with fresh water and then drained to prevent pipe rupture or unnecessary accumulation of solids in the transfer line during long system-idle periods.
[0119] The fill cycle is automatic with manual override. Flow meter monitors the fresh water inflow volume. HSA is added automatically with fresh water at the pre-calculated ratio. Re-fill of the tank is triggered by low-level signal.
[0120] The control of the recovery tank transfer process may be done manually as required. If the transfer causes complete evacuation of the recovery tank, the end of the transfer cycle will trigger the beginning of a new fill cycle. When the tank level drops below a preset minimum, the system may automatically dilute and transfer the remainder of the recovery tank 12 contents to the secondary tank 11 or, alternately, trigger a warning signal to inform the batcher to transfer the remaining volume manually at the batcher's convenience.
[0121] The system monitors system-water density and temperature condition during each irrigation cycle. In SM, a periodic user-defined irrigation cycle monitors and corrects system-water condition. Dramatic changes in conditions can trigger alarms to notify service personnel.
[0122] The system controls operation of an HSA system to inject chemical to the recovery tank as required. In TDM, HSA is added in ratio to fresh water inflow volume, temperature adjusted between 4° C. and 38° C. In HDM, HSA is added in ratio to system-water density and the measured volume of the recovery tank, temperature adjusted between 4° C. and 38° C. In SM, HSA is added in ratio to density in the measured volume of the recovery tank, adjusted by slurry temperature between 4° C. and 38° C.
[0123] For Storage Target Density & Dilution, the density meter has a readout to four decimal places. Target density setting is adjustable from 1.0000 g/cm 3 to 1.3000 g/cm 3 . The target density setting has a threshold of one digit in the second decimal place above and 2 digits below the target density (e.g. If target density is 1.1500, dilution commences when the density reaches 1.1600 and ceases when density drops to 1.1300 or below). The system will not dilute until the recovery circuit is idle. System locks out washout station and re-claimer during dilution.
[0124] The system is arranged to provide a Transfer Target Density and to effect Dilution from that target density during transfer from the tank 12 to the tank 11 , for this purpose, recovery target storage density will always be higher than secondary target batch density. This will always require some degree of dilution as slurry is transferred from the recovery to the secondary tank. As the transfer cycle begins, the system will check the slurry density in the transfer line and begin to introduce fresh dilution water to reduce the storage density in-flow to the batch density. The transfer valve 30 will open at the target batch density and allow batch slurry transfer to the secondary tank. Storage density and batch density can be user-defined.
[0125] In the fill cycle, when the ULI senses that the recovery tank 12 volume has dropped to its minimum level, an automatic refill cycle will commence if the last recorded density measurement is above 1.10 g/cm 3 . The cycle will begin with a purge transfer of the final volume in the recovery tank. The procedure is as follows. The system will check the level in the secondary tank 11 to ensure there is sufficient capacity to accept the final transfer. If capacity is sufficient, slurry will be diluted and transferred to the secondary tank and refill will commence. If capacity is insufficient, the system awaits override by the batcher or notice of available capacity from the secondary tank ULI. While the system is awaiting override or notice, a transfer/purge signal flashes on the OCP screen to notify the batcher of the impending transfer.
[0126] When capacity becomes available, dilution-transfer and refill will commence. The batcher can manually dismiss the transfer notice and return the recovery circuit to normal operation. This manual-dismiss command will cause addition of fresh water and a corresponding quantity of chemical to bring the recovery tank volume to a preset level above the minimum level. Each time the recovery tank volume drops below the preset level it will trigger a transfer notice.
[0127] During the final volume dilution and transfer, the ULI monitors the tank levels. When the volume remaining in the tank reaches 100 gallons, the density measurement and dilution will cease. The secondary transfer line will remain open and the pump will, for example, continue to transfer for 60 seconds. Fresh water induction valve commences refill process. When the period ends, the transfer valve closes and the pump stops, but the fresh water service continues to fill the tank. Flow meter commences to measure fresh water inflow. The flow meter will totalize the fresh water volume inflow until the recovery tank reaches the preset minimum metered volume at which time the fresh water fill valve will close. The closing of the fresh water fill valve will trigger the start of a 3-minute chute rinse irrigation cycle. The irrigation cycle will allow the system to determine density and temperature. The temperature and metered water volume determine the amount of chemical added to the fresh water. The density measurement resets the agitator speed. The rinse cycle ends switching off the pump and closing all recovery and transfer valves.
[0128] The Agitator 26 speed is controlled by the PLC to correlate system-water density with impeller speed. As the density fluctuates, so does agitator speed. The agitator 26 will automatically switch off when the level in the tank drops below a preset limit. Conversely, when the level rises above the preset limit, the agitator will recommence operation.
[0129] A dilution cycle begins when the density in tank 12 rises 0.01 g/cm 3 above the target setting. The re-claimer and wash station valves 20 D and 20 E are locked out. The system transfers 2000 liters of fresh water into the tank. Chemical is added at the pre-calculated ratio according to volume and temperature of fresh water. The addition of chemical is recorded and totalized. A chute rinse cycle will commence to measure density. If density is below 1.13 g/cm 3 , system moves to next step. If density is above 1.13 g/cm 3 , system adds more dilution water and chemical. Dilution sequence repeats until the desired target density is reached. The re-claimer and wash station valves 20 D and 20 E will be unlocked.
[0130] When the ULI senses that the recovery tank has reached maximum allowable volume at the target storage density, recovery tank controls will switch to HDM. Switching to HDM mode will commence a transfer-warning signal at the OCP to advise the batcher to transfer a quantity of system-water to create capacity in the recovery tank for further dilution and addition of washout solids. The transfer warning will continue until the batcher transfers enough volume to the secondary tank to terminate the HDM. In HDM, dilution water is no longer added as density rises. The system monitors density and temperature during HDM and adds chemical according to an HDM I chemical addition scaling function. This will automatically determine the amount of chemical to be added according to the density modified by temperature.
[0131] As required by the batcher, system-water is transferred to the secondary tank in quantity sufficient for the batching requirements for the period concerned, which may be daily/hourly and the system-water then becomes batch-slurry. The batcher inputs a transfer quantity into transfer screen on OCP. The transfer command is initiated, causing the system to lockout all other functions. The primary pump 20 C starts, allowing the density meter to read the system-water density and commence dilution. The fresh water valve 38 B will open until the density measured by the density meter reaches the target batch-slurry density. The transfer valve will open causing the dilute batch-slurry to be transferred into the secondary tank. The transfer will continue until the volume transferred reaches the quantity input by the batcher in step 2 above.
[0132] The transfer valve closes and the system returns to idle.
[0133] When the batcher requires system-water to be transferred to the secondary tank for storage as batch slurry, the dilution-transfer command will allow controlled density system-water to be transferred from the recovery to the secondary tank. The secondary tank 11 will store and monitor the condition of the batch-slurry in the secondary stage before it is sent to the batch plant for use as mixing water. Volume and capacity are monitored and displayed at the OCP. Temperature and density are monitored and displayed at OCP. Batch slurry age is monitored while system is in sleep mode.
[0134] The transfer pump delivers the batch-slurry to batch tank. Transfer is automatically initiated by the level indicator in batch tank.
[0135] For Hydration Stabilization, a user-defined slurry-age timer counts down to re-dosage when the system is in sleep mode. HSA is added automatically to prolong the cementitious life of the batch slurry and prevent hydration from recommencing.
[0136] The batch tank holds a just-in-time volume of batch-slurry for delivery to the weigh hopper at the batch plant. The batch tank has an agitator to keep solids in suspension. The batch tank has a ULI to monitor tank batch-slurry volume. The batch tank refills automatically when volume drops below a preset level. The recycled-water port on the batch computer controls the batch tank discharge valve.
[0137] The density of the batch-slurry in the secondary tank will control the agitator speed. The system will use the target batch density setting to control agitator speed. The batch tank agitator will be constant speed. When the level in either the secondary or the batch tanks drop below a preset limit, the agitator will automatically switch off. Conversely, when the level rises above the limit, the agitator will recommence operation.
[0138] The ULI continuously relays volume in the tank to the PLC. The program continuously calculates available tank capacity. Internal clock monitors the age of the batch-slurry from the time the system switches to sleep mode. When the tank volume drops below a pre-set point the secondary circuit is disabled including operation of the secondary transfer pump.
[0139] If the system is in SM when the clock reaches its re-dosage point a command to add HSA is executed. HSA is added in ratio to the target batch density in the measured volume of the secondary tank adjusted by batch-slurry temperature between 4° C. and 38° C. The real time slurry age clock is reset to zero, counting down to another dosage. This can be repeated a preset number of times defined by the user.
[0140] When the batcher activates the transfer circuit, the transfer pump 52 delivers a quantity of batch-slurry from the secondary tank to the batch tank. The ULI in the batch tank informs the system when the batch tank has filled to a preset maximum level and the system shuts-off the transfer pump. Each time the batch tank calls for batch-slurry, the secondary transfer pump 52 automatically commences transferring.
[0141] When the batcher terminates the use of the transfer circuit, the refill command at batch tank is disabled. The system automatically commences a purge cycle. The purge cycle demands the evacuation of the batch tank and closure of the gate valve 53 on the secondary tank. The ULI will terminate the agitator operation when the batch tank level drops below a preset level, and when the ULI at the batch tank reads that the batch tank is empty, a purge cycle will commence. Fresh water valves (not shown) open in the transfer line for a preset time, allowing the line and pump 52 to be purged with fresh water. Batch slurry is displaced from the transfer pipe and pump casing into batch tank 14 by fresh water. When purging is complete, the system may be set to SM.
[0142] The system can monitor and control the temperature of the slurry by activating an optional heat transfer unit (not shown) mounted in the recovery and/or secondary tank. This heating system will raise the temperature of the system-water or batch-slurry from ambient temperature to the required batch temperature. A temperature sensor is mounted in the secondary tank to monitor slurry temperature. The density meter in the recovery tank also monitors slurry temperature. The PLC controls the heat exchange unit(s). The system has a temperature management program to sense and adjust temperature automatically. Batch-slurry is kept at a temperature that balances efficiency of hydration stabilizer usage and cost of BTU's. Batch-slurry temperature can be raised as it is weighed into the batch by blending with high-temperature water.
[0143] If the producer requires temperature control, optional in-line heat exchangers or in-tank baffle-style heat exchangers may be employed. If the slurry temperature drops below or rises above the setting defined by the producer, the heat exchanger(s) will commence operation. The system tracks the recovery tank system-water temperature at the density meter waiting for it to exceed the preset temperature minimum or maximum. The system tracks the secondary tank batch-slurry temperature with a thermal sensor waiting for it to exceed the preset temperature minimum or maximum.
[0144] Each time the volume in the batch tank 14 drops below a preset minimum, the secondary transfer pump 52 will start delivery of slurry from the secondary tank. When the secondary tank 11 drops below a preset minimum volume, the transfer command from the batch tank will be disabled. The secondary batch transfer circuit will not be locked out, but the batcher will be notified by a red flashing icon that the batch-slurry is not yet up to temperature. The recovery transfer circuit will function regardless of temperature. When the batch-slurry reaches temperature, the flashing icon will turn green to signal that operating temperature has been reached. The batcher may now transfer the batch-slurry to batch. The heat exchanger(s) will raise/lower the temperature of the batch-slurry in the tank(s). When the slurry is 5° C. over/under the system prescribed temperature the heat exchanger will be disabled.
[0145] While the preferred embodiments of the invention have been described above, it will be recognized and understood that various modifications may be made therein, and the appended claims are intended to cover all such modifications which may fall within the spirit and scope of the invention. | A method for recovering usable material from waste concrete is herein described. Specifically, waste concrete is mixed with water containing hydration stabilization admixtures, forming an aggregate slurry. The aggregates are then removed from the slurry for recycling. The slurry itself is then used for mixing with additional waste concrete, during which time the density of the slurry is monitored and action taken to ensure that the density of the slurry remains within acceptable parameters. The slurry is then used in place of fresh water when preparing subsequent batches of concrete. | 1 |
BACKGROUND OF THE INVENTION
The invention relates to a glass object having an encodable layer, as well as to a method of providing a layer on a glass object. The invention further relates to a method of encoding a glass object. Said glass object may be, for example, a front panel of a display tube or a cone of a cathode ray tube.
In general, glass is encoded by providing it with paper stickers on which the code is printed. A disadvantage of these paper stickers is that they cannot withstand processes in which the glass is subjected to heat, because they are burned at high temperatures.
OBJECTS AND SUMMARY OF THE INVENTION
It is an object of the invention to provide a glass object having an encodable label which is resistant to high temperatures. To this end, the object in accordance with the invention is characterized in that it at least comprises a layer which includes glass and pigment. A layer in accordance with the invention can be made, for example, by providing a paste comprising a binder, pigment and glass frit onto hot glass (the glass for example being at a temperature between 400° C. and 600° C., in particular at a temperature of approximately 500 degrees). As the label is resistant to high temperatures, it can be provided early in the production process of the glass product, so that said product can be monitored during the entire, process and after said process.
These and other aspects of the invention will be apparent from and elucidated with reference to the embodiments described hereinafter.
BRIEF DESCRIPTION OF THE DRAWINGS
In the drawing:
The sole FIGURE shows a display tube on which labels are provided.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
The Figure shows a display tube comprising a front panel (1) and a cone (2), which are both provided with a label. In this case, a label is provided on the side face of the front panel and on the side face of the large end portion of the cone. However, the labels may alternatively be provided in other locations. The size of a label can be such that it can contain information from the manufacturer and from the customer. Thus, both the manufacturer and the customer can provide their codes on the same label. The manufacturer can also provide a separate label for use by the customer.
In accordance with the invention, a glass object, for example a front panel of a display tube, is provided, while it is still hot (at a temperature of e.g. between 400° C. and 600° C., in particular approximately 500° C.), with a paste by means of e.g. a roller. Said paste hardens to form a label in which a code can be provided at any time (for example by local ablation by means of a laser).
This paste comprises three components:
a binder (for example an organic binder)
pigment
glass frit (pulverized glass)
The binder makes it possible to apply (spread) the paste. The pigment provides the contrast necessary to read the code. The glass frit is used to adhere the pigment to the glass object. During the provision of the paste on the hot glass (and immediately afterwards) the binder disappears from the mixture. Simultaneously, the frit melts and then crystallizes, thereby causing the pigment to adhere to the glass object.
During the provision of the paste, and immediately afterwards, the binder disappears from the mixture as a result of burning and decomposition, whereafter the substances formed volatize. The binder should not be burnt too vehemently to avoid the formation of cracks in the glass. If the glass is transferred to the cooling furnace, where it is first heated to 600° C. and subsequently cooled slowly to allow stresses to disappear, even more binder material disappears from the applied paste until substantially no paste remains in the mixture.
The pigment should adhere well, be scratch-resistant and exhibit sufficient contrast in the range of the lightspectrum where reading will take place. This can be, for example, the red region of the spectrum, if use is made of a customary bar code reader. It can also be the entire visible spectrum, if reading takes place with the unaided eye. Since it should be possible to recycle the glass, certain substances, for example, substances which color the glass (such as iron, manganese and sulphur) or weaken it, are preferably substantially absent from the glass. In the case of glass display tubes and front panels, there is a list of substances which must not be present in the material used to manufacture these glass display tubes and front panels. For other glass products there are other lists. For example, in glass used for bottles, specific dyes may (and sometimes must) be present; the glass used for bottles does not have to be as strong as that used for cathode ray tubes which are to be evacuated, but it is important that said glass does not contain certain toxic substances. For example, for labels for glass display tubes and front panels, use can be made of the pigment titanium dioxide. This is a white pigment which provides sufficient contrast for reading with the unaided eye or with a bar code reader. If the glass is recycled and the substance is present in diluted form in the newly made glass, it no longer has a coloring effect. Another possibility, which provides a good contrast for reading with the unaided eye, is the use of a layer which is mixed with a black pigment and which is applied on top of a layer with a white pigment, the black pigment being removed selectively. In this manner, a black code on a white background is obtained. Also the reverse is possible. If only a bar code reader is employed for reading, use can alternatively be made of a red pigment. This bar code reader is a standard product which can be easily obtained. Reading can be carried out, for example, by means of a camera, a scanner or a handscanner. Also use can be made of a pigment that changes colour when treated in a particular way. Then the code is applied by locally treating the pigment in said particular way. The colour can for instance be changed from white to black, from black to white or from red to black.
The advantage of providing objects with codes is that these objects can be monitored during the production process and after they have left the factory. During the production process, data such as day, time, press, shift, type of object, production conditions, can be encoded on the product, for example, by means of a laser. These data, or additional data, can also be recorded in a computer file, so that they can be coupled to the code on the product in an easy and unequivocal manner. An embodiment, for example, would be to read a code by means of a handscanner, whereafter information about the object is displayed on the display screen of a computer coupled to said scanner.
Monitoring individual objects during the production process and recording information about these objects can be advantageous during:
testing the effect of changes in the production process.
finding the cause of a defect in a defective object.
tracing other defective objects.
In the production process, the object, for example a glass front panel, is subjected to a number of production steps, in which the machines used are set in a specific manner. The setting of the machines influences the properties of the object. It is often desirable that these properties are substantially constant and that an optimum, with the associated tolerance, is established and maintained. For this purpose, feedback between the measured properties of the object and the setting during the sub-processes is necessary.
There are several reasons why it is advantageous to use the coding process in accordance with the invention during, for example, the production process of front panels:
the front panels can be identified very early in the process, so that the consequences of any changes in specific settings can be tested rapidly and reliably.
panels which look the same, but which have different properties can be manufactured, partly or completely, on the same production line, or they can be stored together since the type of panel can be indicated on the label.
panels can be supplied to a customer (set maker), which are provided with a code which the set maker can employ for his internal process, or a space can be left blank where the set maker can provide a code of his own.
the panels can be monitored from beginning to end with the same label.
after panels have passed through the cooling furnaces (where they can pass each other) it can be established what happened before they were introduced into said cooling furnaces.
A preferred embodiment of the invention is a label which is manufactured in the manner described in this document, and which can be provided with information by the manufacturer and the buyer of the product. In the case of glass front panels, the label can be provided on the side face of the panel. However, there is no fixed location. In order that both the manufacturer and the buyer can use the same label, arrangements must be made regarding the location of the label. It should be provided in such a manner that both the manufacturer and the buyer can readily adapt their treatment processes to said label. | The invention relates to a method of providing an encodable layer on a glass object and on the resultant product. The layer is formed by providing a paste containing glass frit, pigment and a binder, on the hot glass. As a result, the glass frit melts, causing the pigment to adhere to the glass object. The binder, which is used to render the paste spreadable, disappears from the mixture. | 8 |
FIELD OF THE INVENTION
[0001] The present invention generally relates to polymeric amides and imides useful as pour point depressants and their use in providing oils with improved low temperature flow properties.
BACKGROUND OF THE INVENTION
[0002] The present invention generally relates to oil compositions, primarily to fuel oil and petroleum compositions produced there from susceptible to wax formation at low temperatures, to polymeric amides for use with such fuel oil compositions, and to methods for their manufacture.
[0003] Fuel oils and/or petroleum products, whether derived from petroleum or vegetable sources, contain components, e.g., paraffins, alkanes, etc. that at low temperature tend to precipitate as large crystals or spherulites of wax in such a way as to form a gel structure which causes the oil to lose its ability to flow. The lowest temperature at which the fuel will still flow is known as the pour point.
[0004] As the temperature of the fuel falls and approaches the pour point, difficulties arise in transporting the fuel through lines and pumps. Further, the wax crystals tend to plug fuel lines, screens, and filters at temperatures above the pour point. These problems are well recognized in the art, and various additives have been proposed, many of which are in commercial use, for depressing the pour point of fuel oils. Similarly, other additives have been proposed and are in commercial use for reducing the size and changing the shape of the wax crystals that do form. Smaller size crystals are desirable since they are less likely to clog a filter. The wax from a diesel fuel, which is primarily an alkane wax, crystallizes as platelets; certain additives inhibit this and cause the wax to adopt an acicular habit, the resulting needles being more likely to pass through a filter than are platelets. The additives may also suspend in the fuel the crystals that have formed, the resulting reduced settling also assisting in prevention of blockages.
[0005] Effective wax crystal modification (as measured by cold filter plugging point (CFPP),(ASTM D97-66) and other operability tests, as well as simulated and field performance are known in the art. However, there is a continual need in the art to produce more effective polymers giving improved performance.
[0006] Surprisingly, the present inventors have found more effective and economical additives. In particular, applicant has found that certain polymeric amides can effectively and economically be employed as pour point depressants for various grades of crude and fuel oil.
SUMMARY OF THE INVENTION
[0007] The present invention generally relates to an oil composition having improved low temperature properties comprising oil and an effective amount of a pour point depressant additive composition that comprises at least one pour point depressant additive of formula (I), (II) or (III):
wherein R 1 , R 2 and R 3 are independently selected from hydrocarbyl groups containing up to 50 carbon atoms, R 4 is selected from NH or O, and n is an integer of from 0 to 50.
[0008] The invention also relates to a pour point depressant additive composition, a pour point depressant additive concentrate composition and a method of improving the low temperature flow properties of a composition that comprises in major part at least one oil, said method comprising admixture of the composition comprising said at least one oil with an effective amount of the aforementioned pour point depressant additive and/or additive concentrate.
DETAILED DESCRIPTION OF THE INVENTION
[0009] The present invention generally relates to a pour point depressant additive composition that comprises at least one polymeric amide as hereinafter described.
[0010] In a second aspect, this invention relates to a pour point depressant additive concentrate composition comprising the aforementioned pour point depressant additive and a compatible solvent thereof.
[0011] In a third aspect, the invention provides an oil composition with improved low temperature flow properties comprising oil and a amount of the aforementioned pour point depressant additive and/or additive concentrate.
[0012] In a fourth embodiment the invention relates to a method of improving the low temperature flow properties of a composition that comprises in major part at least one oil, said method comprising admixture of the composition comprising said at least one oil with an effective amount of the aforementioned pour point depressant additive and/or additive concentrate.
[0013] The pour point depressant additive of the present invention comprises at least one polymeric amide of General Formulae I, II or III:
wherein R 1 , R 2 and R 3 are independently selected from hydrocarbyl groups containing up to 50 carbon atoms, R 4 is selected from NH or O and n is an integer of from 0 to 50.
[0014] As used herein the term “hydrocarbyl” refers to a group having a carbon atom directly attached to the rest of the molecule and having a hydrocarbon or predominantly hydrocarbon character. Among these, there may be mentioned hydrocarbon groups, including aliphatic, (e.g., alkyl), alicyclic (e.g., cycloalkyl), aromatic, aliphatic and alicyclic-substituted aromatic, and aromatic-substituted aliphatic and alicyclic groups. Aliphatic groups can be saturated or unsaturated. These groups may contain non-hydrocarbon substituents provided their presence does not alter the predominantly hydrocarbon character of the group. Examples include keto, halo, hydroxy, nitro, cyano, alkoxy and acyl. If the hydrocarbyl group is substituted, a single (mono) substituent is preferred. Examples of substituted hydrocarbyl groups include 2-hydroxyethyl, 3-hydroxypropyl, 4-hydroxybutyl, 2-ketopropyl, ethoxyethyl, and propoxypropyl. The groups may also or alternatively contain atoms other than carbon in a chain or ring otherwise composed of carbon atoms. Suitable hetero atoms include, for example, nitrogen, sulphur, and, preferably, oxygen. Advantageously, the hydrocarbyl group contains at most 36, preferably at most 15, more preferably at most 10 and most preferably at most 8, carbon atoms.
[0015] In one embodiment R 1 is a C 6 -C 40 saturated or unsaturated substituted or unsubsituted alkyl group; R 2 is a C 6 -C 30 saturated or unsaturated substituted or unsubsituted alkyl group; and n is an integer of from 1-30. In another embodiment R 1 is a C 8 -C 24 saturated or unsaturated substituted or unsubsituted alkyl group; R 2 is a C 8 -C 24 saturated or unsaturated substituted or unsubsituted alkyl group; and n is an integer of from 1-20. In still another embodiment R 1 is a C 12 -C 22 saturated or unsaturated substituted alkyl group; R 2 is a C 12 -C 22 saturated or unsaturated substituted or unsubsituted alkyl group; and n is an integer of from 1-10
[0016] The products of the present invention are generally prepared by reacting an (a) alpha olefin with (b) maleic anhydride in the presence of a free radical initiator such as, for example, tert-butyl peroxybenzoate (other free radical initiators useful in the context of the present invention are known to those skilled in the art) in order to form (c) a high molecular weight copolymer. This copolymer is then reacted with an (d) amine optionally in the presence of an alcohol, glycol, or a compound that yields an alcohol or glycol in situ (for example an epoxide) in order to form the compound of formula (I).
[0017] It is understood that any alpha olefin of varying carbon chain length can be employed in order to make the products of the invention. In one embodiment the a) alpha olefin is a C 6 -C 24 alpha olefin; in another embodiment it is a C 12 -C 24 alpha olefin and still another it is a C 20 -C 24 alpha olefin.
[0018] In one embodiment the high molecular weight copolymer is of the formula:
[0019] The amines employable in the reaction with the high molecular weight copolymer can be any amine commercially available that reacts with such copolymer, including but not limited to primary, secondary and tertiary amines. Preferably, the amine is of the formula:
where R 4 is an alkylene group of from 6 to 30 carbon atoms. Nonlimiting examples of amines suitable for use include but are not limited to tallowamine, hydrogenated tallowamine, cocoamine, soyamine, oleylamine, octadecylamine, hexadecylamine, dodecylamine, 2-ethylhexylamine, dicocoamine, ditallowamine, dehydrogenated tallowamine, didecylamine, dioctadecylamine, N-coco-1,3-diaminopropane, N-tallow-1,3-diaminopropane, N,N,N-trimethyl-N-tallow-1,3-diaminopropane, N-oleyl-1,3-diaminopropane, N,N<N-trimethyl-N-9-octadecenyl-1,3-diaminopropane, 3-tallowalkyl-1,3-hexahydropyrimidine and mixtures thereof.
[0020] The reaction of the high molecular weight copolymer and amine is generally conducted in the presence of at least one alcohol and/or glycol and/or a substance that yields an alcohol and/or glycol in situ, for example, an epoxide. Alcohols and/or glycols generally contain from 1 up to 50 carbon atoms. In one embodiment of the invention, alcohols/glycols that can usefully be employed include, but are not limited to methanol, ethanol, propanol, isopropanol, butanol, isobutanol C 10 -C 20+ alcohol blends. C 12 -C- 36 Guerbet alcohols, Behenyl alcohols and mixtures thereof.
[0021] The polymer may be made by any of the methods known in the art, e.g., by solution polymerization with free radical initiation, or by high pressure polymerization, conveniently carried out in an autoclave or a tubular reactor.
[0022] Advantageously, polymerization is effected in the following manner. In order to prepare the amide of structure (I), the alcohol is mixed with the amine at any molar ratio to form a mixture of amide and ester. The amount of attachment may vary from 0.1 to 1.0 moles of combined alcohol and amine for each mole of maleic anhydride employed. These half ester structures are then made by mixing the high molecular weight copolymer with amine/alcohol mixture. This mixture is normally heated to 100-200° C. to form the half ester. As an example, one could react 0.5 moles of tallowamine and 0.5 moles of behenyl alcohol for each mole of maleic anhydride in order to get the polymer of formula (I). In one embodiment, examples of preferred amides that can be usefully employed in the context of the present invention include, but are not limited to amides derived from the reaction of at least one of the following amines with maleic anhydride: tallowamine, hydrogenated tallowamine, cocoamine, soyamine, oleylamine, octadecylamine, hexadecylamine, dodecylamine, 2-ethylhexylamine, dicocoamine, ditallowamine, dehydrogenated tallowamine, didecylamine, dioctadecylamine, N-coco-1,3-diaminopropane, N-tallow-1,3-diaminopropane, N,N,N-trimethyl-N-tallow-1,3-diaminopropane, N-oleyl-1,3-diaminopropane, N,N<N-trimethyl-N-9-octadecenyl-1,3-diaminopropane, 3-tallowalkyl-1,3-hexahydropyrimidine and mixtures thereof.
[0023] In order to prepare the amide ester of formula (II), the alcohol is mixed with the amines at any alcohol/amine ratio to form a mixture of amide+ester. The amount of attachment may vary from 0.1 to 2.0 moles of combined alcohol and amine for each mole of maleic anhydride employed. The full ester structure is then made by reacting the copolymer with the amine/alcohol which can be run at any water-producing temperature with or without solvent. Some imide may also be formed by this process. In one embodiment, examples of preferred amides+esters that can be usefully employed in the context of the present invention include, but are not limited to amides+esters derived from the reaction maleic anhydride with at least one of the following amines: tallowamine, hydrogenated tallowamine, cocoamine, soyamine, oleylamine, octadecylamine, hexadecylamine, dodecylamine, 2-ethylhexylamine, dicocoamine, ditallowamine, dehydrogenated tallowamine, didecylamine, dioctadecylamine, N-coco-1,3-diaminopropane, N-tallow-1,3-diaminopropane, N,N,N-trimethyl-N-tallow-1,3-diaminopropane, N-oleyl-1,3-diaminopropane, N,N<N-trimethyl-N-9-octadecenyl-1,3-diaminopropane, 3-tallowalkyl-1,3-hexahydropyrimidine and mixtures thereof in combination with the alcohols: methanol, ethanol, propanol, isopropanol, butanol, isobutanol C 10 -C 20+ alcohol blends, C 12 -C- 36 Guerbet alcohols, Behenyl alcohols and mixtures thereof.
[0024] As indicated above, the polymeric amides of the invention may contain a mixture of different species. It is also within the scope of the invention to provide a composition comprising a mixture of two or more of said polymers.
[0025] The pour point depressant additive of the present invention is especially useful in crude and/or fuel oils having a relatively high wax content, e.g., a wax content of 0.1 to 20% by weight per weight of fuel, preferably 3.0 to 4.5, such as 3.5 to 4.5% wt, measured at 10° C. below wax appearance temperature (WAT).
[0026] The polymer is preferably soluble in the oil to the extent of at least 10,000 ppm by weight per weight of oil at ambient temperature. However, at least some of the additive may come out of solution near the cloud point of the oil and function to modify the wax crystals that form.
[0027] The pour point depressant additive of the present invention can be employed alone, or it may be combined with other additives for improving low temperature flowability and/or other properties, which are in use in the art or known from the literature. The pour point depressant additive composition may also comprise additional cold flow improvers, including but not limited to comb polymers, polar nitrogen compounds, compounds containing a cyclic ring system, hydrocarbon polymer, polyoxyalkylene compounds, mixtures thereof and the like.
[0028] Comb polymers—are polymers in which branches containing hydrocarbyl groups are pendant from a polymer backbone, and are discussed in “Comb-Like Polymers. Structure and Properties”, N. A. Plate and V. P. Shibaev, J. Poly. Sci. Macromolecular Revs., 8, p 117 to 253 (1974), which is incorporated herein by reference.
[0029] Generally, comb polymers have one or more long chain hydrocarbyl branches, e.g., oxyhydrocarbyl branches, normally having from 10 to 30 carbon atoms, pendant from a polymer backbone, said branches being bonded directly or indirectly to the backbone. Examples of indirect bonding include bonding via interposed atoms or groups, which bonding can include covalent and/or electrovalent bonding such as in a salt.
[0030] Advantageously, the comb polymer is a homopolymer or a copolymer having at least 25 and preferably at least 40, more preferably at least 50, molar per cent of the units of which have side chains containing at least 6, and preferably at least 10, atoms.
[0031] These comb polymers may be copolymers of maleic anhydride or fumaric or itaconic acids and another ethylenically unsaturated monomer, e.g., an alpha-olefin, including styrene, or an unsaturated ester, for example, vinyl acetate or homopolymer of fumaric or itaconic acids. It is preferred but not essential that equimolar amounts of the comonomers be used although molar proportions in the range of 2 to 1 and 1 to 2 are suitable. Examples of olefins that may be copolymerized with e.g., maleic anhydride, include 1-decene, 1-dodecene, 1-tetradecene, 1-hexadecene, and 1-octadecene.
[0032] The acid or anhydride group of the comb polymer may be esterified by any suitable technique and although preferred it is not essential that the maleic anhydride or fumaric acid be at least 50% esterified. Examples of alcohols which may be used include n-decan-1-ol, n-dodecan-1-ol, n-tetradecan-1-ol, n-hexadecan-1-ol, and n-octadecan-1-ol. The alcohols may also include up to one methyl branch per chain, for example, 1-methylpentadecan1-ol or 2-methyltridecan-1-ol. The alcohol may be a mixture of normal and single methyl branched alcohols. It is preferred to use pure alcohols rather than the commercially available alcohol mixtures but if mixtures are used the R 12 refers to the average number of carbon atoms in the alkyl group; if alcohols that contain a branch at the 1 or 2 positions are used R 12 refers to the straight chain backbone segment of the alcohol.
[0033] These comb polymers may especially be fumarate or itaconate polymers and copolymers such for example as those described in EP-A-153176, -153177 and -225688, and WO 91/16407.
[0034] Particularly preferred fumarate comb polymers are copolymers of alkyl fumarates and vinyl acetate, in which the alkyl groups have from 12 to 20 carbon atoms, more especially polymers in which the alkyl groups have 14 carbon atoms or in which the alkyl groups are a mixture of C 14 /C 16 alkyl groups, made, for example, by solution copolymerizing an equimolar mixture of fumaric acid and vinyl acetate and reacting the resulting copolymer with the alcohol or mixture of alcohols, which are preferably straight chain alcohols. When the mixture is used it is advantageously a 1:1 by weight mixture of normal C 14 and C 16 alcohols. Furthermore, mixtures of the C 14 ester with the mixed C 14 /C 16 ester may advantageously be used. In such mixtures, the ratio of C 14 to C 14 /C 16 is advantageously in the range of from 1:1 to 4:1, preferably 2:1 to 7:2, and most preferably about 3:1, by weight. The particularly preferred comb polymers are those having a number average molecular weight, as measured by vapor phase osmometry, of 1,000 to 100,000, more especially 1,000 to 30,000.
[0035] Other suitable comb polymers are the polymers and copolymers of alpha-olefins and esterified copolymers of styrene and maleic anhydride, and esterified copolymers of styrene and fumaric acid; mixtures of two or more comb polymers may be used in accordance with the invention and, as indicated above, such use may be advantageous. Other examples of comb polymers are hydrocarbon polymers, e.g., copolymers of ethylene and at least one alpha-olefin, the alpha-olefin preferably having at most 20 carbon atoms, examples being n-decene-1 and n-dodecene-1. Preferably, the number average molecular weight of such a copolymer is at least 30,000 measured by GPC. The hydrocarbon copolymers may be prepared by methods known in the art, for example using a Ziegler type catalyst.
[0036] Polar nitrogen compounds. Such compounds are oil-soluble polar nitrogen compounds carrying one or more, preferably two or more, substituents of the formula >NR 13 , where R 13 represents a hydrocarbyl group containing 8 to 40 atoms, which substituent or one or more of which substituents may be in the form of a cation derived therefrom. The oil soluble polar nitrogen compound is generally one capable of acting as a wax crystal growth inhibitor in fuels, it comprises for example one or more of the following compounds:
[0037] An amine salt and/or amide formed by reacting at least one molar proportion of a hydrocarbyl-substituted amine with a molar proportion of a hydrocarbyl acid having from 1 to 4 carboxylic acid groups or its anhydride, the substituent(s) of formula >NR 13 being of the formula—NR 13 -R 14 where R 13 is defined as above and R 14 represents hydrogen or R 13 , provided that R 13 and R 14 may be the same or different, said substituents constituting part of the amine salt and/or amide groups of the compound.
[0038] Ester/amides may be used, containing 30 to 300, preferably 50 to 150, total carbon atoms. These nitrogen compounds are described in U.S. Pat. No. 4,211,534. Suitable amines are predominantly C 12 to C 40 primary, secondary, tertiary or quaternary amines or mixtures thereof but shorter chain amines may be used provided the resulting nitrogen compound is oil soluble, normally containing about 30 to 300 total carbon atoms. The nitrogen compound preferably contains at least one straight chain C 8 to C 40 , preferably C 14 to C 24 , alkyl segment.
[0039] Suitable amines include primary, secondary, tertiary or quaternary, but are preferably secondary. Tertiary and quaternary amines only form amine salts. Examples of amines include tetradecylamine, cocoamine, and hydrogenated tallow amine. Examples of secondary amines include dioctadecyl amine and methylbehenyl amine. Amine mixtures are also suitable such as those derived from natural materials. A preferred amine is a secondary hydrogenated tallow amine, the alkyl groups of which are derived from hydrogenated tallow fat composed of approximately 4% C14, 31% C16, and 59% C18.
[0040] Examples of suitable carboxylic acids and their anhydrides for preparing the nitrogen compounds include ethylenediamine tetraacetic acid, and carboxylic acids based on cyclic skeletons, e.g., cyclohexane-1,2-dicarboxylic acid, cyclohexene-1,2-dicarboxylic acid, cyclopentane-1,2-dicarboxylic acid and naphthalene dicarboxylic acid, and 1,4-dicarboxylic acids including dialkyl spirobislactones. Generally, these acids have about 5 to 13 carbon atoms in the cyclic moiety. Preferred acids useful in the present invention are benzene dicarboxylic acids e.g., phthalic acid, isophthalic acid, and terephthalic acid. Phthalic acid and its anhydride are particularly preferred. The particularly preferred compound is the amide-amine salt formed by reacting 1 molar portion of phthalic anhydride with 2 molar portions of dihydrogenated tallow amine. Another preferred compound is the diamide formed by dehydrating this amide-amine salt.
[0041] Other examples are long chain alkyl or alkylene substituted dicarboxylic acid derivatives such as amine salts of monoamides of substituted succinic acids, examples of which are known in the art and described in U.S. Pat. No. 4,147,520, for example, which is incorporated herein by reference. Suitable amines may be those described above.
[0042] Other examples are condensates, for example, those described in EP-A-327427.
[0000] Compounds containing a cyclic ring system—carrying at least two substituents of the general formula below on the ring system
—A—NR 15 R 16
where A is a linear or branched chain aliphatic hydrocarbylene group optionally interrupted by one or more hetero atoms, and R 15 and R 16 are the same or different and each is independently a hydrocarbyl group containing 9 to 40 atoms optionally interrupted by one or more hetero atoms, the substituents being the same or different and the compound optionally being in the form of a salt thereof. Advantageously, A has from 1 to 20 carbon atoms and is preferably a methylene or polymethylene group. Such compounds are described in WO 93/04148.
Hydrocarbon polymer. Examples of suitable hydrocarbon polymers are those of the general formula
TR 6
wherein T=H or UR 12 wherein R 21 =C 1 to C 40 hydrocarbyl, and U=H, T, or aryl and v and w represent mole fractions, v being within the range of from 1.0 to 0.0, w being in the range of from 0.0 to 1.0.
[0043] The hydrocarbon polymers may be made directly from monoethylenically unsaturated monomers or indirectly by hydrogenating polymers from polyunsaturated monomers, e.g., isoprene and butadiene. Examples of hydrocarbon polymers are disclosed in WO 91/11488.
[0044] Preferred copolymers are ethylene alpha-olefin copolymers, having a number average molecular weight of at least 30,000. Preferably the alpha-olefin has at most 28 carbon atoms. Examples of such olefins are propylene, n-butene, isobutene, n-octene-1, isooctene-1, n-decene-1, and n-dodecene-1. The copolymer may also comprise small amounts, e.g., up to 10% by weight, of other copolymerizable monomers, for example olefins other than alpha-olefins, and non-conjugated dienes. The preferred copolymer is an ethylene-propylene copolymer.
[0045] The number average molecular weight of the ethylene alphaolefin copolymer is, as indicated above, preferably at least 30,000, as measured by gel permeation chromatography (GPC) relative to polystyrene standards, advantageously at least 60,000 and preferably at least 80,000. Functionally no upper limit arises but difficulties of mixing result from increased viscosity at molecular weights above about 150,000, and preferred molecular weight ranges are from 60,000 and 80,000 to 120,000.
[0046] Advantageously, the copolymer has a molar ethylene content between 50 and 85 per cent. More advantageously, the ethylene content is within the range of from 57 to 80%, and preferably it is in the range from 58 to 73%; more preferably from 62 to 71%, and most preferably 65 to 70%.
[0047] Preferred ethylene alpha-olefin copolymers are ethylene-propylene copolymers with a molar ethylene content of from 62 to 71% and a number average molecular weight in the range 60,000 to 120,000; especially preferred copolymers are ethylene-propylene copolymers with an ethylene content of from 62 to 71% and a molecular weight from 80,000 to 100,000.
[0048] The copolymers may be prepared by any of the methods known in the art, for example using a Ziegler type catalyst. The polymers should be substantially amorphous, since highly crystalline polymers are relatively insoluble in fuel oil at low temperatures.
[0049] Other suitable hydrocarbon polymers include a low molecular weight ethylene-alpha-olefin copolymer, advantageously with a number average molecular weight of at most 7,500, advantageously from 1,000 to 6,000, and preferably from 2,000 to 5,000, as measured by vapor phase osmometry. Appropriate alpha-olefins are as given above, or styrene, with propylene again being preferred. Advantageously the ethylene content is from 60 to 77 molar per cent, although for ethylene-propylene copolymers up to 86 molar per cent by weight ethylene may be employed with advantage.
[0050] The hydrocarbon polymer may most preferably be an oil-soluble hydrogenated block diene polymer, comprising at least one crystallizable block, obtainable by end-to-end polymerization of a linear diene, and at least one non-crystallizable block, the non-crystallizable block being obtainable by 1,2-configuration polymerization of a linear diene, by polymerization of a branched diene, or by a mixture of such polymerizations.
[0051] Advantageously, the block copolymer before hydrogenation comprises units derived from butadiene only, or from butadiene and at least one comonomer of the formula
CH 2 =CR 1 -CR 2 =CH 2
wherein R 1 represents a C 1 to C 8 alkyl group and R 2 represents hydrogen or a C 1 to C 8 alkyl group. Advantageously the total number of carbon atoms in the comonomer is 5 to 8, and the comonomer is advantageously isoprene. Advantageously, the copolymer contains at least 10% by weight of units derived from butadiene.
[0052] In general, the crystallizable block or blocks will be the hydrogenation product of the unit resulting from predominantly 1,4-or end-to-end polymerization of butadiene, while the non-crystallizable block or blocks will be the hydrogenation product of the unit resulting from 1,2-polymerization of butadiene or from 1,4-polymerization of an alkyl-substituted butadiene.
[0053] A polyoxyalkylene compound. Examples are polyoxyalkylene esters, ethers, ester/ethers and mixtures thereof, particularly those containing at least one, preferably at least two, C10 to C30 linear alkyl groups and a polyoxyalkylene glycol group of molecular weight up to 5,000, preferably 200 to 5,000, the alkyl group in said polyoxyalkylene glycol containing from 1 to 4 carbon atoms. These materials form the subject of EP-A-0 061 895. Other such additives are described in U.S. Pat. No. 4,491,455.
[0054] The preferred esters, ethers or ester/ethers are those of the general formula
R 31 —O (D)—O—R 32
where R 31 and R 32 may be the same or different and represent
(a) n-alkyl- (b) n-alkyl-CO— (c) n-alkyl-O—CO(CH2)x-or p 0 (d) n-alkyl-O—CO(CH2)x-CO—
x being, for example, 1 to 30, the alkyl group being linear and containing from 10 to 30 carbon atoms, and D representing the polyalkylene segment of the glycol in which the alkylene group has 1 to 4 carbon atoms, such as a polyoxymethylene, polyoxyethylene or polyoxytrimethylene moiety which is substantially linear; some degree of branching with lower alkyl side chains (such as in polyoxypropylene glycol) may be present but it is preferred that the glycol is substantially linear. D may also contain nitrogen.
[0058] Examples of suitable glycols are substantially linear polyethylene glycols (PEG) and polypropylene glycols (PPG) having a molecular weight of from 100 to 5,000, preferably from 200 to 2,000. Esters are preferred and fatty acids containing from 10-30 carbon atoms are useful for reacting with the glycols to form the ester additives, it being preferred to use a C18-C24 fatty acid, especially behenic acid. The esters may also be prepared by esterifying polyethoxylated fatty acids or polyethoxylated alcohols.
[0059] Polyoxyalkylene diesters, diethers, ether/esters and mixtures thereof are suitable as additives, diesters being preferred for use in narrow boiling distillates, when minor amounts of monoethers and monoesters (which are often formed in the manufacturing process) may also be present. It is preferred that a major amount of the dialkyl compound be present. In particular, stearic or behenic diesters of polyethylene glycol, polypropylene glycol or polyethylene/polypropylene glycol mixtures are preferred.
[0060] Other examples of polyoxyalkylene compounds are those described in Japanese Patent Publication Nos. 2-51477 and 3-34790, and the esterified alkoxylated amines described in EP-A-117,108 and EP-A-326,356.
[0061] It is within the scope of the invention to use two or more additional flow improvers advantageously selected from one or more of the different classes outlined above.
[0062] If an additional flow improver is employed, it is advantageously employed in a proportion within the range of from 0.01% to 1%, advantageously 0.05% to 0.5%, and preferably from 0.075 to 0.25%, by weight, based on the weight of fuel.
[0063] The pour point depressant additive of the invention may also be used in combination with one or more other co-additives such as known in the art, for example the following: detergents, particulate emission reducers, storage stabilizers, antioxidants, corrosion inhibitors, dehazers, demulsifiers, antifoaming agents, cetane improvers, cosolvents, package compatibilizers, and lubricity additives.
[0064] Additive concentrates according to the invention advantageously contain between 3 and 75%, preferably between 10 and 65%, of the pour point depressant additive in an oil or a solvent miscible with oil.
[0065] The concentrate comprising the additive in admixture with a suitable solvent are convenient as a means for incorporating the additive into bulk oil such as distillate fuel, which incorporation may be done by methods known in the art. The concentrates may also contain the other additives as required and preferably contain from 3 to 75 wt %, more preferably 3 to 60 wt %, most preferably 10 to 50 wt % of the additives preferably soluble in oil. Examples of solvent are organic solvents including hydrocarbon solvents, for example petroleum fractions such as naphtha, kerosene, diesel and heater oil; aromatic hydrocarbons such as aromatic fractions, e.g. those sold under the ‘SOLVESSO’ tradename; alcohols and/or esters; and paraffinic hydrocarbons such as hexane and pentane and isoparaffins. The solvent must, of course, be selected having regard to its compatibility with the additive and with the oil.
[0066] The oil, preferably crude oil or fuel oil, composition of the invention advantageously contains the pour point depressant polymer of the invention in a proportion of 0.0005% to 1%, advantageously 0.001 to 0.1%, and preferably 0.01 to 0.06% by weight, based on the weight of oil.
[0067] In one embodiment, the oil-containing composition of the invention comprises crude oil, i.e. oil obtained directly from drilling and before refining.
[0068] The oil may be a lubricating oil, which may be an animal, vegetable or mineral oil, such, for example, as petroleum oil fractions ranging from naphthas or spindle oil to SAE 30, 40 or 50 lubricating oil grades, castor oil, fish oils, oxidized mineral oil, or biodiesels. Such oils may contain additives depending on its intended use; examples are viscosity index improvers such as ethylene-propylene copolymers, succinic acid based dispersants, metal containing dispersant additives and zinc dialkyldithiophosphate antiwear additives. The pour point depressant of this invention may be suitable for use in lubricating oils as a flow improver, pour point depressant or dewaxing aid.
[0069] In another embodiment the oil is a fuel oil, e.g., a petroleum-based fuel oil, especially a middle distillate fuel oil. Such distillate fuel oils generally boil within the range of from 110° C. to 500° C., e.g. 150° C. to 400° C. The fuel oil may comprise atmospheric distillate or vacuum distillate, cracked gas oil, or a blend in any proportion of straight run and thermally and/or catalytically cracked distillates. The most common petroleum distillate fuels are kerosene, jet fuels, diesel fuels, heating oils and heavy fuel oils. The heating oil may be a straight atmospheric distillate, or it may contain minor amounts, e.g. up to 35 wt %, of vacuum gas oil or cracked gas oil or of both. The above-mentioned low temperature flow problem is most usually encountered with diesel fuels and with heating oils. The invention is also applicable to vegetable-based fuel oils, for example rapeseed oil, used alone or in admixture with a petroleum distillate oil. The invention will now be illustrated by the following nonlimiting example.
EXAMPLE 1
[0070] Aromatic 150 (about 25% by weight of the product), C-20-24 Alpha Olefin (1.0 mole), and Maleic Anhydride (1.15 moles) are stirred in a flask equipped with an inert nitrogen subsurface sparge to eliminate air from the product and overhead and set for total reflux. The mixture is heated to 130° C. and then tert-butyl peroxybenzoate (0.02 moles) is slowly added continuously over a two to three hour period while maintaining the temperature at 130° C. and then allowed to react in for an additional hour. The flask is then set to collect distillate and the premelted tallowamine (1.15 moles) is then added to the mixture allowing the exotherm along with external heating to hold the product at 150° C. for 2 hours. The resulting product was tested as a potential wax crystalline modifier against our current product (PC-105) used for this application. The pour point test results (attached) show that the experimental product (labeled RLC-2) was better at 200 ppm treating levels than our current PC-105 (labeled RLC-1) at 600 ppm treating levels. When the experimental product was used at the 600 ppm treating levels, it was even more effective (i.e. reduced the pour point of the crude all the way to 20° F.) at reducing the pour point of the crude that would normally not flow at 70° F. without treatment.
[0071] The pour point test results are compiled in Table 1, below.
TABLE 1 Sample Analysis (D5853-95, Procedure 9.1.5) Test Description: Akzonobel Pour Point Depressant Evaluation Sample ID GoM Crude GoM Crude GoM Crude GoM Crude GoM Crude Sample Description: No Additive 200 ppm RLC-1 600 ppm RLC-1 200 ppm RLC-2 600 ppm RLC-2 Start Time 9:17 9:17 9:17 9:17 9:17 Start Temp. 120 F. 120 F. 120 F. 120 F. 120 F. Bath 2 (70° F.) Time: 13:00 115° F. Flowing Flowing Flowing Flowing Flowing 110° F. ✓ ✓ ✓ ✓ ✓ 105° F. ✓ ✓ ✓ ✓ ✓ 100° F. ✓ ✓ ✓ ✓ ✓ 95° F. ✓ ✓ ✓ ✓ ✓ 90° F. ✓ ✓ ✓ ✓ ✓ 85° F. ✓ ✓ ✓ ✓ ✓ Bath 3 (32° F.) Time: 13:50 80° F ✓ ✓ ✓ ✓ ✓ 75° F. ✓ ✓ ✓ ✓ ✓ 70° F. No No Flow ✓ ✓ ✓ Flow 65° F. □ □ ✓ ✓ ✓ 60° F. □ □ No Flow ✓ ✓ 55° F. □ □ ✓ ✓ 50° F. □ □ □ ✓ ✓ Bath 4 (0° F.) Time: □ □ □ □ 14:44 45° F. □ □ □ ✓ ✓ 40° F. □ □ □ No Flow ✓ 35° F. □ □ □ □ ✓ 30° F. □ □ □ □ ✓ 25° F. □ □ □ □ ✓ 20° F. □ □ □ □ ✓ 15° F. □ □ □ □ No Flow Bath 5 (−27° F.) Time: 10° F. □ □ □ □ □ 5° F. □ □ □ □ □ | The present invention generally relates to oil compositions, primarily to fidel oil and petroleum compositions produced there from susceptible to wax formation at low temperatures, to polymeric amides for use with such fuel oil compositions, and to methods for their manufacture. | 2 |
This application is a continuation of U.S. patent application Ser. No. 10/965,444 filed Oct. 12, 2004 which claims priority to provisional application No. 60/511,145 filed Oct. 14, 2003; provisional application No. 60/511,144 filed Oct. 14, 2003; provisional application No. 60/511,143 filed Oct. 14, 2003; provisional application No. 60/511,142 filed Oct. 14, 2003; provisional application No. 60/511,141 filed Oct. 14, 2003; provisional application No. 60/511,140 filed Oct. 14, 2003; provisional application No. 60/511,139 filed Oct. 14, 2003; provisional application No. 60/511,138 filed Oct. 14, 2003; provisional application No. 60/511,021 filed Oct. 14, 2003; and provisional application No. 60/563,262 filed Apr. 16, 2004, all of which are incorporated herein by reference in their entirety.
FIELD OF THE INVENTION
The field of the invention is network switches.
BACKGROUND
Modern computer networks typically communicate using discrete packets or frames of data according to predefined protocols. There are multiple such standards, including the ubiquitous TCP and IP standards. For all but the simplest local topologies, networks employ intermediate nodes between the end-devices. Bridges, switches, and/or routers, are all examples of intermediate nodes.
As used herein, a network switch is any intermediate device that forwards packets between end-devices and/or other intermediate devices. Switches operate at the data link layer (layer 2 ) and sometimes the network layer (layer 3 ) of the OSI Reference Model, and therefore typically support any packet protocol. A switch has a plurality of input and output ports. Although a typical switch has only 8, 16, or other relatively small number of ports, it is known to connect switches together to provide large numbers of inputs and outputs. Prior art FIG. 1 shows a typical arrangement of switch modules into a large switch that provides 128 inputs and 128 outputs.
One problem with simple embodiments of the prior art design of FIG. 1 is that failure of any given switch destroys integrity of the entire switching system. One solution is to provide entire redundant backup systems (external redundancy), so that a spare system can quickly replace functionality of a defective system. That solution, however, is overly expensive because an entire backup must be deployed for each working system. The solution is also problematic in that the redundant system must be engaged upon failure of substantially any component within the working system. Another solution is to provide redundant modules within the system, and to deploy those modules intelligently (internal redundancy). But that solution is problematic because all the components are situated locally to one another. A fire, earthquake or other catastrophe will still terminally disrupt the functionality of the entire system.
U.S. Pat. No. 6,256,546 to Beshai (March 2002) describes a protocol that uses an adaptive packet header to simplify packet routing and increase transfer speed among switch modules. Beshai's system is advantageous because it is not limited to a fixed cell length, such as the 53 byte length of an Asynchronous Transfer Mode (ATM) system, and because it reportedly has better quality of service and higher throughput that an Internetworking Protocol (IP) switched network. The Beshai patent, is incorporated herein by reference along with all other extrinsic material discussed herein
Prior art FIG. 1A depicts a system according to Beshai's '546 patent. There, pluralities of edge modules (ingress modules 110 A-D and egress modules 130 A-D) are interconnected by a passive core 120 . Each of the ingress modules 110 A-D accept data packets in multiple formats, adds a standardized header that indicates a destination for the packet, and switches the packets to the appropriate egress modules 130 A-D through the passive core 120 . At the egress modules 130 A-D the header is removed from the packet, and the packet is transferred to a sink in its native format. The solid lines of 112 A- 112 D depict unencapsulated information arriving to circuit ports, ATM ports, frame relay ports, IP ports, and UTM ports. Similarly, the solid lines of 132 A-D depict unencapsulated information exiting to the various ports in the native format of the information. The dotted lines of core 120 and facing portions of the ingress 110 A-D and egress 130 A-D modules depict information that is contained UTM headed packets. The entire system 100 operates as a single distributed switch, in which all switching is done at the edge (ingress and egress modules).
Despite numerous potential advantages, Beshai's solution in the '546 patent has significant drawbacks. First, although the system is described as a multi-service switch (with circuit ports, ATM ports, frame relay ports, IP ports, and UTM ports), there is no contemplation of using the switch as an Ethernet switch. Ethernet offers significant advantages over other protocols, including connectionless stateful communication. A second drawback is that the optical core is contemplated to be entirely passive. The routes need to be set up and torn down before packets are switched across the core. As such Beshai does not propose a distributed switching fabric, he only discloses a distributed edge fabric with optical cross-connected cores. A third, related disadvantage, is that Beshai's concept only supports a single channel from one module to another. All of those deficiencies reduce functionality.
Beshai publication no. 2001/0006522 (Jul. 2001) resolves one of the deficiencies of the '546 patent, namely the single channel limitation between modules. In the '522 application Beshai teaches a switching system having packet-switching edge modules and channel switching core modules. As shown in prior art FIG. 1B , traffic entering the system through ports 162 A is sorted at each edge module 160 A-D, and switched to various core elements 180 A-C via paths 170 . The core elements switch the traffic to other destination edge modules 180 A-C, for delivery to final destinations. Beshai contemplates that the core elements can use channel switching to minimize the potential wasted time in a pure TDM (time division mode) system, and that the entire system can use time counter co-ordination to realize harmonious reconfiguration of edge modules and core modules.
Leaving aside the switching mechanisms between and within the core elements, the channel switching core of the '522 application provides nothing more than virtual channels between edge devices. It does not switch individual packets of data. Thus, even though the '522 application incorporates by reference Beshai's Ser. No. 09/244824 application regarding High-Capacity Packet Switch (issued as U.S. Pat. No. 6,721,271 in April 2004), the '522 application still fails to teach, suggest, or motivate one of ordinary skill to provide a fully distributed network (edge and core) that acts as a single switch.
What is still needed is a switching system in which the switching takes place both at the distributed edge nodes and within a distributed core, and where the entire system acts as a single switch.
SUMMARY OF THE INVENTION
The present invention provides apparatus, systems, and methods in which the switching takes place both at the distributed edge nodes and within a distributed core, and where the entire system acts as a single switch through encapsulation of information using a special header that is added by the system upon ingress, and removed by the system upon egress.
The routing header includes as least a destination element address, and preferably also includes a destination port address, a source element address. Where the system is configured to address clusters of elements, the header also preferably includes a destination cluster address and a source cluster address.
The ingress and egress elements preferably support Ethernet or other protocol providing connectionless media with a stateful connection. At least some of the ingress and egress elements preferably have least 8 input ports and 8 output ports, and communicate at a speed of at least one, and more preferably at least 10 Gbs.
Preferred switches include management protocols for discovering which elements are connected, for constructing appropriate connection tables, for designating a master element, and for resolving failures and off-line conditions among the switches. Secure data protocol (SDP), port to port (PTP) protocol, and active/active protection service (AAPS) are all preferably implemented.
Systems and methods contemplated herein can advantageously use Strict Ring Topology (SRT), and conf configure the topology automatically. Other topologies can be can alternatively or additionally employed. Components of a distributed switching fabric can be geographically separated by at least one kilometer, and in some cases by over 150 kilometers.
Various objects, features, aspects and advantages of the present invention will become more apparent from the following detailed description of preferred embodiments of the invention, along with the accompanying drawings in which like numerals represent like components.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1A is a schematic of a prior art arrangement of switch modules that cooperate to act as a single switch.
FIG. 1B is a schematic of a prior art arrangement of switch modules connected by an active core, but where the modules operate independently of one another.
FIG. 2 is a schematic of a true distributed fabric switching system, in which edge elements add or remove headers, and the core actively switches packets according to the headers.
FIG. 3 is a schematic of a routing header.
FIG. 4 shows a high level design of a preferred combination Ingress/Egress element
FIG. 5 shows a high level design of a preferred core element
FIG. 6 is a schematic of a Raptor™ 1010 switch.
FIG. 7 is a schematic of a Raptor™ 1808 switch.
FIG. 8 is a schematic of an exemplary distributed switching system according to preferred aspects of the present invention.
FIG. 9 is a schematic of a super fabric implementation of a distributed switching fabric.
DETAILED DESCRIPTION
In FIG. 2 a switching system 200 generally includes ingress elements 210 A-C, egress elements 230 A-C, core switching elements 220 A-C and connector elements 240 A-C. The ingress elements encapsulate incoming packets with a routing header (see FIG. 3 ), and perform initial switching. The encapsulated packets then enter the core elements for further switching. The intermediate elements facilitate communication between core elements. The egress elements remove the header, and deliver the packets to a sink or final destination.
Those skilled in the art will appreciate that switching (encapsulation) header must, at a bare minimum, include at least a destination element address. In preferred embodiments the header also includes destination port ID, and where elements are clustered and optional destination cluster ID. Also optional are fields for source cluster, source element, and source port IDs. As used herein an “ID” is something that is the same as, or can be resolved into an address. In FIG. 3 a preferred switching header 300 generally includes a Destination Cluster ID 310 , a Destination Element ID 320 , a Destination Port ID 330 , a Source Cluster ID 340 and a Source Element ID 350 . In this particular example, the each of the fields has a length of at least 1 byte and up to 2 bytes. Those skilled in the art should also appreciate that the term “header” is used here as in a euphemistic sense to mean any additional routing data that is included in a package that encapsulates other information. The header need not be located at the head end of the frame or packet.
Ingress 210 A-C and egress 230 A-C elements are shown in FIG. 2 as distinct elements. In fact, they are similar in construction, and they may be implemented as a single device. Such elements can have any suitable number of ports, and can operate using any suitable logic. Currently preferred chips to implement the design are Broadcom's™ BCM5690, BCM5670, and BCM5464S chips, according to the detailed schematics included in one or more of the priority provisional applications.
FIG. 4 shows a high level design of a preferred combination ingress/egress element 400 , which can be utilized for any of the ingress 210 A-C and egress 230 A-C elements. Ingress/Egress element 400 generally includes a logical switching frame 410 , Ethernet ingress/egress ports 420 A-L, encapsulated packet I/O port 430 , layer 2 table(s) 440 , layer 3 table(s) 450 , and access control table(s) 460 .
Ingress/egress elements are the only elements that are typically assigned element IDs. When packets arrive at an ingress/egress port 420 , it is assumed that all ISO layer 2 fault parameters are satisfied and the packet is correct. The destination MAC address is searched in the layer 2 MAC table 440 , where the destination element ID and destination port ID are already stored. Once matched, the element and port IDs are placed into the switching header, along with the destination cluster ID, and source element ID. The resulting frame is then sent out to the core element.
When an encapsulated frame arrives, the ID is checked to make sure the packet is targeted to the particular element at which it arrived. If there is a discrepancy, the frame is checked to determine whether it is a multicast or broadcast frame. If it is a multicast frame, the internal switching header is stripped and the resulting packet is copied to all interested parties (registered IGMP “Internet Group Management Protocol” joiners). If it is a broadcast frame, the RAST header is stripped, and the resulting packet is copied to all ports except the incoming port over which the frame arrived. If the frame is a unicast frame, the element ID is stripped off, and the packet is cut through to the corresponding physical port.
Although ingress/egress elements could be single port, in preferred embodiments they would typically have multiple ports, including at least one encapsulated packet port, and at least one standards based port (such as Gigabit Ethernet). Currently preferred ingress/egress elements include 1 Gigabit Ethernet multi-port modules, and 10 Gigabit Ethernet single port modules. In other aspects of preferred embodiments, an ingress/egress element may be included in the same physical device with a core element. In that case the device comprises a hybrid core-ingress/egress device. See FIGS. 6 and 7 .
FIG. 5 shows a high level design of a preferred core element 500 , which can be utilized for any of the core switching elements 220 A-C. Core element 500 generally includes a logical switching frame 510 , a plurality of ingress and/or egress ports 520 A-H, one or more unicast tables 530 , one or more multicast tables 540 .
When an encapsulated frame arrives at an ingress side of any port in the core element, the header is read for the destination ID. The ID is used to cut through the frame to the specific egress side port for which the ID has been registered. The unicast table contains a list of all registered element IDs that are known to the core element. Elements become registered during the MDP (Management Discovery Protocol) phase of startup. The multicast table contains element IDs that are registered during the “discovery phase” of a multicast protocol's joining sequence. This is where the multicast protocol evidences an interested party, and uses these IDs to decide which ports take part in the hardware copy of the frames. If the element ID is not known to this core element, or the frame is designated a broadcast frame, the frame floods all egress ports.
Connector elements 240 A-C (depicted in FIG. 2 as RAST™, for Raptor Adaptive Switch Technology™ Header), are low level devices that allow the core elements to communicate with other core elements over cables or fibers. They assist in enforcing protocols, but have no switching functions. Examples of such elements are XAU1 over copper connectors XAU1/XGmil over fiber connectors using MSA XFP.
FIG. 6 is a schematic of a preferred commercial embodiment of a hybrid core-ingress device, designated as a Raptor™ 1010 switch. The switch 600 generally includes two 10 GBase ingress elements 610 A-B, two ingress elements other than 10 GBase 615 A-B, a core element 620 , and intermediate connector elements 630 A-D. The system is capable of providing 12.5 Gbps throughput.
FIG. 7 is a schematic of a preferred commercial embodiment of a hybrid core-ingress device, designated as a Raptor™ 1808 switch. The switch 700 could include eight 10 GBase ingress elements 710 A-D, a core element 720 , or eight intermediate connector elements 730 A-D, or any combination of elements up to a total of eight.
In FIG. 8 a switching system 800 includes two of the Raptor™ 1010 switches 600 A-B and four of the Raptor™ 1808 switches 700 A-D, as well as connecting optical or other lines 810 . The lines preferably comprise a 10 GB or greater backplane. In this embodiment the links between the 1010 switches can be 10-40 km at present, and possibly greater lengths in the future. The links between the core switches can be over 40 km.
Ethernet
A major advantage of the inventive subject matter is that it implements switching of Ethernet packets using a distributed switching fabric. Contemplated embodiments are not strictly limited to Ethernet, however. It is contemplated, for example, that an ingress element can convert SONET to Ethernet, encapsulate and route the packets as described above, and then convert back from Ethernet to SONET.
Topology
Switching systems contemplated herein can use any suitable topology. Interestingly, the distributed switch fabric contemplated herein can even support a mixture of ring, mesh, star and bus topologies, with looping controlled via Spanning Tree Avoidance algorithms.
The presently preferred topology, however, is a Strict Ring Topology (SRT), in which there is only one physical or logical link between elements. To implement SRT each source element address is checked upon ingress via any physical or logical link into a core element. If the source element address is the one that is directly connected to the core element, the data stream will be blocked. If the source element address is not the one that is directly connected to this core element, the package will be forwarded using the normal rules. A break in the ring can be handled in any of several known ways, including reversion to a straight bus topology, which would cause an element table update to all elements.
Management of the topology is preferably accomplished using element messages, which can advantageously be created and promulgated by an element manager unit (EMU). An EMU would typically manage multiple types of elements, including ingress/egress elements and core switching elements.
Management Discovery Protocol
In order for a distributed switch fabric to operate, all individual elements need to discover contributing elements to the fabric. The process is referred to herein as Management Discovery Protocol (MDP). MDP discovers fabric elements that contain individual management units, and decides which element become the master unit and which become the backup units. Usually, MDP needs to be re-started in every element after power stabilizes, the individual management units have booted, and port connectivity is established. The sequence of a preferred MDP operation is as follows:
Each element transmits an initial MDP establish message containing its MAC address and user assigned priority number (if assigned 0 used if not set). Each element also listens for incoming MDP messages, containing such information. As each element receives the MDP messages, one of two decisions is made. If the received MAC address is lower than the MAC address assigned to the receiving element, the message is forwarded to all active links with the original MAC address, the link number it was received on, and the MAC address of the system that is forwarding the message. If a priority is set, the lowest priority (greater than 0) is deemed as lowest MAC address and processed as such. If on the other hand the received MAC address is higher than the MAC address assigned to the receiving element, then the message is not forwarded. If a priority is set that is higher than the received priority, the same process is carried out
Eventually the system identifies the MAC address of the master unit, and creates a connection matrix based on the MAC addresses of the elements discovered, the active port numbers, and the MAC addresses of each of the elements, as well as each of their ports. This matrix is distributed to all elements, and forms the base of the distributed switch fabric. The matrix can be any reasonable size, including the presently preferred support for a total of 1024 elements.
As each new element joins an established cluster, it issues a MDP initialization message, which is answered by a stored copy of the adjacency table. The new element insert its own information into the table, and issues an update element message to the master, which in turn will check the changes and issue an element update message to all elements.
Heart Beat Protocol
Heart Beat Protocol enables the detection of a faked element. If an element fails or is removed from the matrix, a Heart Beat Protocol (HBP) can be used to signal that a particular link to an element is not in service. Whatever system is running the HBP sends an element update message to the master, which then reformats the table, and issues an element update message to all elements.
It is also possible that various pieces of hardware will send an interrupt or trap to the manager, which will trigger an element update message before HBP can discover the failure. Failure likely to be detected early on by hardware include; loss of signal on optical interfaces; loss of connectivity on copper interfaces; hardware failure of interface chips. A user selected interface disable command or shutdown command can also be used to trigger an element update message.
Traffic Load
Traffic Load factors can be calculated in any suitable manner. In currently preferred systems and methods, traffic load is calculated by local management units and periodically communicated in element load messages to the master. It is contemplated that such information can be used to load balance multiple physical or logical links between elements.
Security
Element messages are preferably sent using a secure data protocol (SDP), which performs an ACK/NAK function on all messages to ensure their delivery. SDP is preferably operated as a layer 2 secure data protocol that also includes the ability to encrypt element messages between elements.
As discussed elsewhere herein, element messages and SDP can also be used to communicate other data between elements, and thereby support desired management features. Among other things, element messages can be used to support Port To Port Protocol (PTPP), which provides a soft permanent virtual connection to exist between element/port pairs. As currently contemplated, PTPP is simply an element-to-element message that sets default encapsulation to a specific element address/port address for source and destination. PTPP is thus similar to Multiprotocol Label Switching (MPLS) in that it creates a substitute virtual circuit. But unlike MPLS, if a failure occurs, it is the “local” element that automatically re-routes data around the problem. Implemented in this manner, PTPP allows for extremely convenient routing around failures, provided that another link is available at both the originating (ingress) side and the terminating (egress) side, and there is no other blockage in the intervening links (security/Access Control List (ACL)/Quality of Service (QoS), etc),
It is also possible to provide a lossless failover system that will not lose a single packet of data in case of a link failure. Such a system can be implemented using Active/Active Protection Service (AAPS), in which the same data is sent in a parallel fashion. The method is analogous to multicasting in that the hardware copies data from the master link to the secondary link. Ideally, the receiving end of the AAPS will only forward the first copy of any data received (correctly) to the end node.
Super Fabric
Large numbers of elements can advantageously be mapped together in logical clusters, and addressed by including destination and source cluster IDs in the switching headers. In one sense, cluster enabled elements are simply normal elements, but with one or more links that are capable of adding/subtracting cluster address numbers. A system that utilizes clusters in this manner is referred to herein as a super fabric. Super fabrics can be designed to any reasonable size, including especially a current version of super fabric that allows up to 255 clusters of 1024 elements to be connected in a “single” switch system.
As currently contemplated, the management unit operating in super fabric mode retains details about all clusters, but does not MAC address data. Inter-cluster communication is via dynamic Virtual LAN (VLAN) tunnels which are created when a cluster level ACL detects a matched sequence that has been predefined. Currently contemplated matches include any of: (a) a MAC address or MAC address pairs; (b) VLAN ID pairs; (c) IP subnet or subnet pair; (d) TCP/UDP Protocol numbers or pairs, ranges etc; (e) protocol number(s); and (f) layer 2 - 7 match of specific data. The management unit can also keep a list of recent broadcasts, and perform a matching operation on broadcasts received. Forwarding of previously sent broadcasts can thereby be prevented, so that after a learning period only new broadcasts will forwarded to other links.
Although clusters are managed by a management unit, they can continue to operate upon failure of the master. If the master management unit fails, a new master is selected and the cluster continues to operate. In preferred embodiments, any switch unit can be the master unit. In cases where only the previous management has failed, the ingress/egress elements and core element are manageable by the new master over an inband connection.
Inter-cluster communication is preferably via a strict PTPP based matrix of link addresses. When a link exists between elements that received encapsulated packets, MDP discovers this link, HBP checks the link for health, and SDP allows communication between management elements to keep the cluster informed of any changes. If all of the above is properly implemented, a cluster of switch elements can act as a single logical Gigabit Ethernet or 10 Gigabit Ethernet LAN switch, with all standards based switch functions available over the entire logical switch.
The above-described clustering is advantageous in several ways.
Link Aggregation IEEE 802.3ad can operate across the entire cluster. This allows other vendors' systems that use IEEE 802.3ad to aggregate traffic over multiple hardware platforms, and provides greater levels of redundancy than heretofore possible. Virtual LANs (VLANs) 802.1Q can operate over the entire cluster without the need for VLAN trunks or VLAN tagging on inter-switch links. Still further, port mirroring (a defacto standard) is readily implemented, providing mirroring of any port in a cluster to any other port in the cluster. Pause frames received on any ingress/egress port can be reflected over the cluster to all ports contributing to the traffic flow on that port, and pause frames can be issued on those contributing ports to avoid bottlenecks. ISO Layer 3 (IP routing) operates over the entire cluster as though it was a single routed hop, even though the cluster may be geographically separated by 160 Km or more. ISO Layer 4 ACLs can be assigned to any switch element in the cluster just as they would be in any standard layer 2 / 3 / 4 switch, and a single ACL may be applied to the entire cluster in a single command. IEEE 802.1X operates over the entire cluster, which would not the case if a standard set of switching systems were connected.
In FIG. 9 , a super fabric implementation 900 of a distributed switching fabric generally includes four 20 Gbps pipes 910 A-D, each of which is connected to a corresponding cluster 920 A-D that includes a control element 922 A-D that understand the cluster messaging structure. Within each cluster there are numerous ingress/egress elements 400 coupled together. In this particular embodiment there each of the control elements 922 A-D has two 10 Gbps pipes that connect the ingress/egress elements 400 for intra-cluster communication. There are also inter-cluster pipes 930 A-D, which in this instance also communicate at 10 Gbps.
Thus, specific embodiments and applications of distributed switching fabric switches have been disclosed. It should be apparent, however, 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 spirit 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. | A switch encapsulates incoming information using a header, and removes the header upon egress. The header is used by both distributed ingress nodes and within a distributed core to facilitate switching. The ingress and egress elements preferably support Ethernet or other protocol providing connectionless media with a stateful connection. Preferred switches include management protocols for discovering which elements are connected, for constructing appropriate connection tables, for designating a master element, and for resolving failures and off-line conditions among the switches. Secure data protocol (SDP), port to port (PTP) protocol, and active/active protection service (AAPS) are all preferably implemented. Systems and methods contemplated herein can advantageously use Strict Ring Topology (SRT), and conf configure the topology automatically. Components of a distributed switching fabric can be geographically separated by at least one kilometer, and in some cases by over 150 kilometers. | 7 |
RELATED APPLICATIONS
This application is a continuation-in-part of copending application Ser. No. 09/563,445 filed May 1, 2000 and titled Method of Transporting, Handling, and Servicing a Racing Car, which in turn was copending with provisional patent application Serial No. 60/132,139, filed May 1, 1999.
TECHNICAL FIELD
This invention pertains to the field of vehicle lifts for servicing an automobile and/or for diagnosing and tuning the chassis of an automobile. The invention also pertains to the field of transporting automobiles in carrier vehicles, loading and unloading automobiles into and from carrier vehicles, and otherwise handling the automobiles. Within those fields, the invention is particularly concerned with transporting racing cars and preparing them for racing, but has application to other vehicles and situations as well, for example transporting antique and classic cars and handling and servicing them at their destination.
BACKGROUND ART
Automobile racing is an extremely popular sport and is becoming more so. In 1998 NASCAR alone had 17 of the 20 best-attended sports events in America, each with an attendance of over 100,000 spectators. Cable television coverage of these events has greatly enlarged the audience, which is continuing to expand by millions of viewers each year. Other types of automobile racing, for example, Grand Prix road racing, drag racing, and endurance racing, are also popular throughout the world. The U.S. retail market for products made specifically for racing has been estimated at $1.5 billion annually. Equally impressive is the number of actual participants in auto racing. It was recently estimated that at least 385,000 people competed in an organized automobile race at least once in 1998.
Teams and individuals who participate in auto racing vary greatly in terms of equipment sophistication, financial and personnel resources, driver skills, and support crew proficiency. While the larger and better-financed competitors receive most of the publicity, a far greater number receive little or no publicity. For many of these participants, responding to the varied challenges presented by the competition provides much of the motivation. If a team or individual is unable to compete one way, they must be resourceful enough to devise other ways to compete, while staying within their particular limitations as well as the rules.
One of these challenges is the efficient use of time and personnel at the track. This challenge is particularly demanding during a racing event or in on-site preparation for a racing event. It is also a factor in preparation and development of the automobile and driver in order to optimize their respective performances for future racing events, since “track time” is usually limited and costly. As best stated by Carroll Smith, “Nothing is ever in such short supply at a race track as time . . . . There is never enough time . . . . Time lost during practice or qualifying is lost forever and time wasted during a day of testing is expensive and frustrating. Especially at one of the $1,000 per day tracks”. (Tune to Win, 1978, page 161. Mr. Smith also authored Engineer to Win in 1984. Both books are incorporated herein by reference.)
Competing for track time are numerous procedures which require accessing and working on or inspecting the undercarriage of the racing car, often repeatedly and with unavoidable interruptions for test driving on the track. These procedures generally fall into three categories which are not mutually exclusive: chassis tuning, safety, and inspection.
Chassis tuning is essential, if the racing car is to even approach its maximum performance capabilities. While the car with the best chassis tuning may not always win the race, chassis tuning often determines the winner, will always determine the winner when other factors are equal, and almost always determine a loser if ignored. Examples of chassis tuning procedures are: diagnosing and correcting chassis binding; disconnecting linkages for front or rear anti-sway bars and exchanging an anti-sway bar (i.e., anti-roll bar or stabilizer bar) for one of a different torsion rate; determining that the rear end of the car is square to the chassis or at a desired offset (i.e., “stringing the car”), changing one or more springs, struts, or shock absorbers to ones with more desirable mechanical properties; setting the front and/or rear ride height; adjusting the front and/or rear camber to the desired degree setting; adjusting the front for camber gain and cross percentages of caster; adjusting the front and/or rear for toe-out or toe-in; adjusting for optimum bump steer; adjusting corner weights (e.g. by adjusting jack screws or wedges); adjusting for optimum Ackerman steering, if the car is so equipped; measuring and optimizing the scrub radius of tires; adjusting control devices for rear axle performance (e g., panhard bar or Watts link); adjusting rear torque arms; adjusting other devices relative to rear axle performance (e.g., to optimize anti-squat, anti-lift, and anti-dive characteristics, rear-steering characteristics, rear camber and rear toe-in); determining optimum weight distributions on each of the car's wheels (i.e., “scaling the car”). Chassis tuning frequently uses known alignment tools, for example, turn plates, caster/camber gages, toe-in devices, and devices for measuring linear distance. Chassis tuning is a process of balancing many interrelated variables to provide optimum handling characteristics and thus ultimate racing performance.
Safety procedures include the following: inspecting fasteners and tightening as necessary; inspecting for oil leaks, gas line leaks, shock absorber malfunctions and correcting as necessary; inspecting brake lines for signs of chafing or failure and correcting as necessary; inspecting brake pads and rotors and servicing as necessary; inspecting the flywheel scatter-shield device; inspecting the drive shaft safety hoop; inspecting for damage or undesirable changes resulting from a track incident.
Routine maintenance procedures include the following changing engine oil; inspecting and/or changing transmission lubricants; inspecting and/or changing final drive lubricants; checking and maintaining the integrity of the exhaust system.
Racing cars are transported to racing events and elsewhere by a variety of means. One such means is a tractor-trailer combination in which an enclosed, two-level trailer carries at least four cars. The cars are loaded and unloaded by an elevatable horizontal platform which is supported by two sets of diagonal chains at the rear of the trailer when in use and folds against the rear of the trailer when not in use. Such transporters are depicted in Old Car Trader, July 1998, pages Y-28 and Y-29, in the advertisements of VIP Transport, Inc. and Exotic Car Transport. We believe that these particular platforms fold about two hinges, in an arrangement similar to that shown by Erlinder U.S. Pat. No. 3,675,739 on a truck.
Also known are mobile lifts for servicing or transporting automobiles. See, for example, Grimaldo U.S. Pat. No. 3,931,895, Cray U.S. Pat. No. 4,445,665, Lapiolahti U.S. Pat. No. 4,750,856, and Wellman U.S. Pat. No. 5,810,544. An example of another, commercially available lift is depicted in Hemmings Motor News, September 1999 issue, page 8879, in an advertisement by Autolifters of America, Inc., Wichita, Kans.
Stationary lifts or grease pits are rarely, if ever, available for the use of contestants at a track. There are currently several methods of elevating racing cars at tracks so that they can be worked on and inspected. One such method utilizes a lever, for example a first class lever with a long handle at one end, a load-supporting surface at the other end, and in between a fulcrum which bears on the pavement. A second method involves four pressurized gas-actuated jacks which are mounted on the racing car itself. A third method consists of jacking up one side or end of the car at a time by one or more jacks which, though having a specialized and sophisticated design, operate much the same way as ordinary garage or vehicle-carried jacks. The first two methods are fast and are often used for raising a car several inches during a race for limited purposes, for example changing tires, but are not suitable for allowing working under the car for most purposes, because of obvious space, stability, and safety limitations. The third method can raise the car somewhat higher, more so if jackstands are used, but is slower and still cannot provide the access and stability made possible by more robust conventional lifts.
Each of these methods has the further disadvantage that raising the car takes the sprung weight of the car off the suspension, so that repairs, modifications, and adjustments which affect the handling of the car must be made under artificial, “no-load” conditions. Moreover, lowering the car back down does not necessarily, and probably will not, return handling-affecting parameters to a condition which allows a useful comparison with their “original condition” that existed just prior to the raising, repair, modifying, or adjustment. Put another way, in these prior art methods the mere acts of raising and lowering change these parameters. Sometimes crew personnel bounce the car up and down while rolling it backward and forward after it has been lowered, in an effort to achieve a comparable condition. This remedy is not reliable; for example, the wheels may not be able to assume their original position without having been driven at track speed with the weight of the driver. Alternatively, the car may be driven on the track again in an attempt to achieve the desired comparable suspension condition, but this remedy involves additional time and expense and may itself introduce some further variable; for example, the suspension may reflect the most recent track condition, vehicle speed, or driver action.
Some racing teams undoubtedly employ sophisticated lifts at their permanent facilities at home, and these lifts may have some degree of mobility. We are not, however, aware of a mobile lift which has been used at a track to (1) raise the car in the horizontal position (with the exception of the on-board jacks mentioned above), (2) raise the car sufficiently high to allow its undercarriage to be worked on and inspected by a person who is not lying on the ground, or (3) raise or lower the car without unloading its suspension. If such use of a mobile lift has taken place, we suspect that the reason it was not adopted for widespread use was that the lift failed to meet one or more requirements for use at a track. These requirements, in my opinion, include a combination of at least two of the following, in no particular order: mobility, compactness, ease and speed of operation, ability to be operated by one or two people, stability, safety, ease and speed of setup and takedown, rigidity, ability to duplicate previous conditions, reliability, versatility, durability, low cost, and ability to accept racing cars which, because of their ground-effects fairing designed to come as close as possible to the surface of the track, have minimal ground clearance.
Aside from lifts, equipment for diagnosing and tuning the chassis of a racing car exists, but apparently little descriptive literature has been made available to the public. We believe that most of such equipment is large, sophisticated, and expensive, and likely to be useful only at a few permanent facilities scattered around the world. Typically such facilities are by leased to well-heeled clients for relatively short periods of time. For obvious competitive reasons both the lessors and the lessees are inclined to maintain in strict secrecy the diagnostic and tuning technology as well as the application thereof to particular racing cars and problems. We are not aware of such diagnostic equipment that is designed for use at a track or has been used at a track.
Spencer-Smith U.S. Pat. No. 6,044,696 discloses portable apparatus for testing and evaluating the performance of racing cars under simulated conditions. The automobile, without wheels and tires, is bolted to the apparatus by its wheel hubs, which of course renders it unable to include wheels or tires in any diagnosis or evaluation. This apparatus does not appear to be suited for use at a track and the patent does not disclose such use, but the apparatus is said to be useful prior to arriving at the track on or just before race day, so as to enable race teams to focus their full attention on chassis set-up after they arrive at the track. The Spencer-Smith apparatus does not have the ability to lift the automobile or permit its undercarriage to be accessed for servicing.
SUMMARY OF THE INVENTION
The invention addresses these requirements and is intended to meet them more successfully than the prior art, by meeting more of the requirements and by meeting individual requirements in a superior manner.
An object of the invention is to provide a mobile lift system which may be used at a track or other race course for servicing a racing car in a horizontal elevated position, in which position the undercarriage of the car may be comfortably and efficiently accessed through an open platform by a person who, since he or she is not required to lie on the ground, has full use of both hands and ergonomically favorable body positioning and leverage.
Another object of the invention is that the system and the racing car may be transported by road to and from the course in a single carrier vehicle, such as a truck or trailer.
Another object of the invention is that the system may be used to load and unload the racing car into and from the carrier vehicle.
Another object of the invention is that the system be capable of elevating the racing car for service in a standalone mode, in which the platform is separated from the carrier vehicle, thereby conforming to the space limitations at most race courses.
Another object of the invention is that the system allow the racing car to be driven from the ground onto the platform and vice versa.
Another object of the invention is that the platform support the racing car by its tires, so as to permit the racing car to be worked on, measured, and tested without taking the sprung weight of the car off its suspension.
Another object of the invention is to use the system to simulate, on a racing car supported by the platform, loads the car is likely to encounter on the race course. While such loads are dynamic and transient on the race course, the system may be used to replicate them and their effects in a static condition, thereby enabling the observation, measurement, comparison, and analysis of the positions and relationships of various components of the car's suspension and steering.
The present invention is a system for handling and servicing a car that has been transported by road to a destination away from a permanent servicing facility at home. Exemplary such destinations include tracks or other race courses and shows and similar events for the transported car. The inventive system employs an open platform for supporting the car by its tires in a horizontal position. The platform supports the car in a carrier vehicle, such as a truck or trailer, when the carrier vehicle is transporting the car to the course. This eliminates the need for an additional carrier vehicle, an additional driver, and the attendant expenses. The platform and a separate tracked or wheeled crawler are used to unload the car from the carrier vehicle onto the ground and to load the car from the ground into the carrier vehicle. In addition, the platform is used at the course or other destination to elevate the car so that its undercarriage is accessible through an opening in the platform and thus may be worked on or inspected to prepare or improve the car for racing or otherwise service the car. These uses are equally well suited to vehicles other than racing cars, for example antique and classic cars being transported to shows, exhibitions, rallies, and the like.
A portion of the system according to the present invention is a lifting platform which has utility at a track irrespective of whether it is used for transporting the racing car. Such utility includes the chassis tuning, safety, and servicing procedures discussed thus far, which have corresponded to procedures which have been performed using a conventional lift to elevate a car. Beyond that, however, the inventive platform enables new procedures to be performed at a track as well as elsewhere We call these new procedures “advanced chassis tuning” or, more specifically, “chassis tuning with constantly loaded suspension”. Essentially these procedures are based on the concept of substituting the elevated platform for a floor, so that chassis tuning procedures can be performed simultaneously with measuring the effects caused by the procedures. For example, weighing simultaneously the four wheels of a racing vehicle is a customary way to measure these effects. Kroll et al. U.S. Pat. No. 5,232,064 discloses portable scales for weighing wheels of racing cars, and it is known that scales of this type may be arranged in a spaced relationship in a fixture which lies on the ground. Such scales may be placed in the deck of the present invention, so that the chassis may be tuned while the car is being weighed. Individually operable legs according to the invention are intended to provide the leveling control necessary for such advanced chassis tuning. Another technique which can be used in advanced chassis tuning on the platform according to the invention is manipulating the racing car to simulate, in a static situation, the positions and loadings the car has experienced or is likely to experience on the track. This is effected by providing input forces to the chassis by a rigid link connecting the undercarriage of the car to the platform. By adjusting and accurately controlling these input forces, various dynamic loads the car will encounter on the track can be simulated
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a left side view of a platform in a fully elevated position.
FIG. 2 is a front view of the platform shown in FIG. 1 .
FIG. 3 is an isometric view of the platform shown in FIG. 1, in a partially elevated position.
FIG. 4 is a section of FIG. 3 taken at 4 — 4 .
FIG. 5A is an enlarged view of the left hand portion of FIG. 4 .
FIG. 5B is a section of FIG. 5A taken at 5 B— 5 B.
FIG. 6 is a side view of an actuator, with a portion of the housing of the actuator body broken away.
FIG. 7A is an isometric view of an actuator connected to the frame of a car at the upper left rear shock absorber mount.
FIG. 7B is an isometric view of an actuator connected to the frame of a car at the left front lower control arm.
FIG. 8 is an isometric view of a tracked crawler.
FIG. 9 is a left side view of a variation of the crawler shown in FIG. 8, which variation does not have tracks.
FIG. 10 is a front view of the crawler shown in FIG. 9, with its ground wheels vertically aligned.
FIG. 11 is a left side view of a platform in a partially elevated position and a tracked crawler centered beneath the platform.
FIG. 12 is a front view of the crawler and platform shown in FIG. 11 .
FIG. 13 is section of FIG. 3 taken at 13 — 13 and a section of FIG. 8 taken at 13 — 13 .
FIG. 14 is a left side view of a piggybacked non-tracked crawler and platform carrying a car and being driven up the ramp of a carrier vehicle.
FIG. 15 is a view similar to FIG. 14, but with the piggybacked crawler and platform entering the carrier vehicle.
FIG. 16 is a view similar to FIG. 15, but with the piggybacked crawler and platform in a transport position in the carrier vehicle.
FIG. 17 is a front view of the crawler, platform, and car shown in FIG. 16 .
The drawings are approximately to scale. The platform actually has a length of 192 inches and a width of 80 inches.
DESCRIPTION OF THE PREFERRED EMBODIMENT
The following terms will be used throughout this application in accordance with these definitions, unless a different interpretation is required by the context.
The terms “automobile” and “car” mean an automobile, truck, or other vehicle which may be transported by road on or in a truck or trailer.
The term “bed”, as applied to a truck or trailer, refers to a surface for supporting a car or other load being transported. A vehicle may have more than one bed.
The term “chassis” means the suspension, steering, alignment, and wheel (including the tire and rim) systems. This definition is consistent with the traditional and formal meaning of “chassis”, but it should be noted that usage of this term in the art is somewhat imprecise and may be different in some prior art patens and other literature.
The term “chassis tuning” means observing, measuring, testing, and/or analyzing the chassis and then effecting any desired adjustment, correction, or servicing thereof
The term “force-multiplying mechanism” means a hydraulic or mechanical device which employs a mechanical advantage to produce a multiplied pushing or pulling force, for example a hydraulic lift mechanism or a jackscrew.
The term “frame”, as applied to a car which does not have a frame distinct from its body, means the structural component of the body of the car which is equivalent to a frame.
The terms “front” and “rear” will be used with reference to the carrier vehicle. That is, the “front” of the platform or car will be closest to the steering wheel of the carrier vehicle when the platform or car is being transported, loaded, or unloaded.
The term “ground” means any substantially flat, solid base, including earth, pavement, floor, or a surface thereon.
The terms “race” and “racing” refer to a race involving competition, either directly (i.e., head-to-head) or by comparison of recorded elapsed times, between cars with drivers.
The term “race car” and “racing car” refer to a car designed, adapted, or otherwise intended for use in racing.
The term “roll” and cognate terms, as applied to moving a car on and off a platform, refer to driving, pushing, pulling, or winching the car.
The terms “track” and “course” refer to any closed circuit or open circuit automobile race course, including circular tracks, oval tracks, figure eight tracks, road racing courses, drag strips, and endurance courses used by an automobile and driver either for racing or for development or preparation for racing.
The term “recording”, as used herein with reference to digital data, includes converting, to digital form, data which was initially recorded as analog data, as well as initially recording data in digital form.
As shown in FIGS. 1-3, racing car 10 having body or frame 12 is supported by its tires 14 on fully elevated platform 20 standing on the ground 16 . A substantially rigid structure is provided by deck 22 welded to transverse members 28 , with two interior access openings, front access opening 30 and rear access opening 32 . Deck plates 22 have a flat, non-skid, top surface, an outer side rail 24 and an inner side rail 26 , so that each deck plate has a downwardly facing C-shaped cross-section. Each deck plate 22 has a rear tapered portion 34 . Transverse members 28 have a rectangular cross-section. Platform 20 is supported and spaced from the ground 16 by four extendible legs 36 , each of which is a part of a leg assembly including foot 38 , foot pin 40 , stabilizer 42 , and knee pivot bushing 44 . Four scales 46 are mounted in deck plates 22 .
As shown in FIGS. 3-5, each leg 36 is extended and retracted by leg assembly motor 48 supported by motor mount 50 . Electric motor 50 is powered by batteries 70 (shown only in FIGS. 4 and 5 ), or alternatively the motor may be hydraulic and powered by an electrically powered pump (not shown). Motor mount 50 is supported by base plate 56 , which is secured either to the inner and outer side rails of deck plate 22 or to the underside of deck plate 22 (see FIG. 5 ). The driveshaft of motor 48 is connected by coupling 52 and reducer bushing 53 to Acme shaft 54 , which is supported and held in position by thrust block 69 attached to base plate 56 . At its right hand end, shaft 54 has external threads 62 , which pass through unthreaded slide block 66 and engage the internal threads of Acme nut 64 .
At the upper end of leg 36 are slide block 66 and studded cam follower 68 . Cam follower 68 bears against, and is in rotating contact with, base plate 56 ; is guided longitudinally by riser 61 ; and is protected by cover plate 57 . Cover plate 57 also keeps cam follower 68 , slide block 66 , and leg 36 from falling away from platform 20 in the event that foot 38 leaves the ground. Slide block 66 is restrained by Acme nut 64 from longitudinal movement away from motor 48 . The upper end of stabilizer 42 is rotatably attached to stabilizer pivot 60 , which is bolted to stabilizer support 58 .
Legs 36 may be extended or retracted, and platform 20 elevated or lowered, by selectively operating motor 48 in the clockwise or counterclockwise direction. Rotation of shaft 54 in one direction drives Acme nut 64 away from motor 48 , with the weight of the platform causing slide block 66 and the upper end of leg 36 to continue to abut Acme nut 48 . As this occurs, foot 38 remains planted on the ground, leg 36 rotates about foot pin 40 to a more horizontal position, and platform 20 is lowered. When motor 48 is operated in the opposite direction, the process is reversed and platform 20 is elevated. In this manner legs 36 may be extended and retracted to move platform 20 , with or without the car on it, to the fully elevated horizontal position shown in FIGS. 1 and 2, to the fully lowered, horizontal, ground position shown by chain lines 20 g , and to various positions between these two positions, for example the intermediate horizontal position shown by chain lines 20 i . Since each leg assembly is driven by its own individual motor, legs 36 may be extended or retracted individually. This permits accurate leveling of platform 20 . In addition, the front legs and the rear legs may be selectively operated so that the rear, tapered portion 34 of platform 20 rests flat on the ground, while the front end of platform 20 is elevated. This position (not shown) allows a car with limited ground clearance between the front and rear wheels to be driven onto the inclined platform without scraping. The use of a threaded shaft and nut as the force-multiplying mechanism enhances the safety and simplicity of the system, since the inherent friction keeps the platform from falling to the ground due to non-catastrophic system failures and avoids the need for engaging a separate locking or safety device when the platform is in a stopped position. Such devices are essential in hydraulic and cable systems. As shown in FIGS. 1 and 2, when platform 20 is in ground position 20 g , the leg assemblies are retracted completely into deck plates 22 . This enables the top surface of platform 20 to get very close to the ground, while keeping the leg assemblies completely under platform 20 as a design parameter.
As shown in FIG. 6, actuator 100 comprises body 104 , shaft 102 , strain gauge 115 , coupling attachment 108 , and mounting bracket 116 . Shaft 102 passes through internal worm gear 110 , which is rotatably mounted on bearings 111 . Actuator motor 106 rotates externally threaded shaft 109 , driving an internal worm gear 110 which translates the actuator shaft 102 linearly in a vertical direction. Shaft 102 does not rotate. Actuator coupling 108 provides an attachment point to the car body. Mounting bracket 116 is attached to the inner side rail 26 or actuator carriers (not shown).
As shown in FIGS. 7A and 7B, the actuator coupling 108 is connected to a point on the car body near a suspension mount. The actuator coupling 108 may be attached directly to the car body or frame or indirectly thereto through a rigid link. As shown in FIG. 7A, front link 120 for the left front of the car is attached to the car's left lower control arm 124 . As shown in FIG. 7B, rear link 122 for the left rear of the car is attached to the top mount of the car's left rear shock absorber 126 . The actuator may then be energized to load the suspension by pulling or pushing to duplicate a desired position of the chassis, for example a measured condition found on the race course. Strain gauges 115 measure the pulling or pushing forces. Scales 46 measure the resulting wheel weights.
Mounting brackets 116 or the actuator carriers attaching each actuator 100 to an inner side rail 26 may be removed and reattached to a different location on inner side rail 26 , so that each actuator 100 can be positioned directly under the point on the car frame where the force is being applied. In addition, actuator 100 and the bracket and/or carrier may be pivotally connected so that when the bracket or carrier is bolted to inner side rail 26 , actuator 100 may be pivoted 90 degrees about a horizontal axis transverse to the longitudinal axis of platform 20 and then locked into one of two positions—the operating position shown in the drawings and a horizontal position parallel to that longitudinal axis, In the latter position, actuator 100 is out of the way, and permits platform 20 to be fully lowered to the ground.
As shown in FIG. 8, tracked crawler 200 has frame 202 comprising side plate 204 , cross-member 206 , and floor 207 . Tracks 214 surround ground wheels 208 , drive wheels 210 , and idler wheels 212 . Drive wheels 210 are driven by electric drive motor 216 , which is powered by batteries 218 connected to control box 222 . Also connected to control box 222 , by cable 221 , is remote control 220 , which has independent controls for driving each track separately and thus serves as a steering mechanism. Positioning pins 224 project upwardly from frame 202 .
As shown in FIGS. 9 and 10, non-tracked crawler 250 has frame 252 and upwardly projecting positioning pins 254 . Instead of tracks, however, crawler 250 has six ground wheels which are in direct contact with the ground. These are rear wheels 256 , center wheels 258 , and front wheels 260 . Rear wheels 256 are driven by roller chains 262 , which in turn are driven by drive sprockets 264 . Tension wheels 266 tension chains 262 . Front wheels 260 and center wheels 258 are mounted on bogies or equalizer arms 268 , which are pivotally connected to frame 222 by axle 270 . Center wheels 258 and front wheels 260 may be driven by tensioned roller chains in a manner (not shown) similar to rear wheels 256 , except that their drive sprockets are coaxial with axle 270 . Hydraulic lift cylinder 272 is connected to frame 252 at its top end and at its bottom end is attached to bogie 268 near center wheel 258 . Like tracked crawler 200 , non-tracked crawler 250 is powered by batteries connected by a control box to motors which drive the drive sprockets (not shown), and the control box is connected to a remote control which is capable of steering crawler 250 by enabling the operator to apply power selectively to the ground wheels on either side or to the ground wheels on both sides simultaneously (not shown). To facilitate turning non-tracked crawler 250 , weight can be concentrated on center ground wheels 258 by applying fluid pressure to lift cylinder 272 , thereby driving center wheels downward and lessening the weight on front wheels 260 .
FIGS. 11-13 show how platform 20 piggybacks on tracked crawler 200 . With platform 20 elevated to an intermediate position, crawler 200 is driven from the position shown by chain lines, between the rear legs of platform 20 , to a centered position between the platform's front and rear legs 36 , so that positioning pins 224 are beneath and aligned with four positioning pin sockets 90 . Then legs 36 are retracted, so that positioning pins 224 engage positioning pin sockets 90 and the weight of the platform (and the car, if the platform is carrying a car) is supported by crawler frame 202 . Then legs 36 are fully retracted into the deck plates. In this piggybacked mode, crawler 200 may be driven on the ground and steered, with the platform and car carried on it.
FIGS. 14-17 show how platform 20 and car 10 piggybacked on non-tracked crawler 250 are driven into a carrier vehicle 300 , which may be a truck or a trailer, via ramp 302 , for transport to a track or other destination.
It is important that the crawler be separable from the platform. While the two could conceivably be integral, creating in effect a motorized, steerable pallet, the result would be that all the machinery for propelling and guiding this apparatus would remain with the platform while it is being used at the track for servicing and tuning cars and the like. As a matter of engineering and design, such integral machinery would have to be either under the platform or beside it, or both. If the integral machinery is beside the platform, then the widths of the platform and the car would have to be limited, since the combination cannot be any wider than the interior width of the carrier vehicle. If the integral machinery is under the platform, then the platform cannot be lowered sufficiently close to the ground to allow cars with limited ground clearance to drive onto it. By enabling the crawler to be withdrawn from beneath the platform, as described earlier, the crawler can be stored in a remote location or driven back into the carrier vehicle and left there while the platform is being used at the track. In addition, the invention allows the separation of the platform and the crawler to be effected by the platform's extendible leg systems, which the platform must have anyway for other purposes, so that no specific machinery is necessary for this purpose. The separation is “free”.
Advanced chassis tuning provides the ability to measure and manipulate chassis parameters outside of the bounds of a simple measurement or a measurement after a single element of suspension geometry has been removed, replaced, or otherwise changed. Advanced chassis tuning covers a range which extends from measuring multiple chassis points, to manipulating those points in a methodical fashion, and finally to manipulating suspension points with active controlled inputs so as to duplicate, in a static testing facility, the dynamic condition of a race car during or in preparation for a racing event.
Thus, advanced chassis tuning can be separated into three stages.
Stage 1 advanced chassis tuning is based upon the concept of placing a race car on a level surface and being able to accurately measure all suspension components and setups without moving the vehicle again. This includes wheel loading, left and right toe angles for both front and rear, left and right camber angles for front and rear, left and right caster angles for both front and rear, left and right kingpin inclination for both front and rear, wheelbase, front and rear track widths, parallelism and squareness of front and rear axle assemblies, and half track widths. The distinguishing feature of Stage 1 chassis tuning is that it is based upon the principle of measuring a static car with no external inputs.
Stage 2 advanced chassis tuning consists of all of the elements of Stage 1 tuning but adds the ability to provide single to multiple inputs. This means that a step or ramp input to the steering or to a chassis member can be applied and all of the measurement capabilities of Stage 1 can be used to determine quantifiable changes to suspension geometry. For example, Ackerman effect is the effect of the left and right wheels turning unequal amounts for a given steering mechanism movement. In Stage 2 tuning, the wheels can be set to a specific turn angle and the chassis could be positioned so as to simulate the car entering a corner. All of the measurement systems can then be used to determine whether any suspension components behave unacceptably. Ideally, four links or other connections are mounted on or immediately adjacent to the suspension mounting points on the chassis. For example, the bolts that provide the pivots for the lower control arms would be ideal and would be unlikely to damage a chassis under test. The load is being applied back through the point which is supposed to support that load.
Stage 2 advanced chassis tuning involves pulling to a data point in time. Traditional loading and computer design programs tend to check only one parameter at a time. That is, they compute the camber, caster, toe-in change as the chassis is lowered or raised, or, they may do the same as steering angle is raised, or the same as dive under braking or squat under acceleration are simulated. In Stage 2 chassis tuning, however, the instantaneous data point in time is based on multiple inputs (steering, single wheel bump, and braking distortion, chassis roll, etc), These inputs can be fed into the chassis and the disturbance to all of the above points (caster, camber, etc.) can be again measured for unusual deviations.
Stage 3 advanced chassis tuning correlates to the incorporation of the data from an onboard data acquisition system to simulate real world chassis conditions. One such system is described in Purnell et al. U.S. Pat. No. 5,173,856. This Purnell et al. patent discloses, among other things, a vehicle data recording system employing analog sensors which sense selected positions and forces during actual driving on a track, converting the analog data into digital data, and storing the digital data in memory. For example, during a test session the car driver reports that the vehicle always slides disconcertingly in a specific corner at a specific point in that corner. Stage 3 tuning allows the simulation of most chassis conditions on a test mechanism back at the pits. In effect, it gives one the ability to “freeze frame” the vehicle. By using four or more measured, stored pieces of data, a Stage 3 chassis tuning device can apply loads and conditions so as to relatively closely approximate the position and load of the suspension components when the undesirable behavior was noticed. Stage 3 allows a chassis specialist to inspect the vehicle in the stressed condition, i.e., “freeze framed” state. Visual inspections can be performed to determine if suspension components are loose or if components have deflected a significant amount under track conditions, or to detect similar readily observable problems. The measurement techniques used in Stage 1 chassis tuning can be brought into play and accurate measurements of all suspension points can be performed in the stressed condition. This information can be used by a race car engineer to determine what chassis components need to be adjusted, replaced, or redesigned.
In addition, the use of four actuators allows one to mimic true chassis behavior on the track to the extent that chassis deformation can be studied. Theoretically only three actuators are required to pull the chassis out of plane. However, the chassis will not be planar under the loads imposed on a racetrack. The fourth actuator will pull the chassis to the stressed condition as recorded by the data acquisition system. Stress and deflections of the chassis can be studied. Chassis modifications to reduce stress can be prototyped on the unit and behavior of the suspension can be altered to be compatible with increased chassis rigidity.
The actuators used in Stage 3 tuning allow simulation of tire performance. Under vertical load, the sidewall of a tire is a spring damper combination. By imposing vertical loading, the static spring rate of a tire can be determined. The vertical spring and damper rate of a tire has a significant effect under acceleration and braking in that ride height of the vehicle is affected which in turn affects roll center and chassis center of gravity. The use of rotating or sliding elements under the scales allows one to look at tire sidewall deformation and tire slip angle. As a tire grips the road in a corner, the sidewall of the tire is pulled out of concentricity with the wheel. Under high cornering load, the tire also has a “slip angle”. “Slip angle” is the difference in the angle of the tire contact patch as measured from the angle of the steering input. Tires must build slip angle to generate lateral holding forces. The elements under the wheels would allow one to either lock those elements and induce lateral loading by turning the steering system or one could add some type of actuator to physically generate slip angle.
An illustrative example of Stage 3 tuning is as follows. Suppose a race driver were to complain that the race car handles unacceptably over a specific track area. The car could be placed on a Stage 3 device and the data points that define that section of track could be recalled. Suppose further that the data points when duplicated by a Stage 3 system left the car positioned and stressed such that one wheel of the car was essentially unloaded. This information cannot be obtained without Stage 3 tuning. Conventional procedures cannot apply the various simultaneous inputs to the vehicle so as to position the car to mimic the track condition. Based on measured suspension location and measured wheel weights, one skilled in race car suspension setup could vary anti-roll bars, shock absorber rates, spring rates, suspension mounting location points, etc. so as to alter the position of the car to achieve a more desirable suspension condition. The more desirable position is difficult to define since there are so many different parameters in racing and a desirable parameter on one track may not be desirable on another.
In addition, once a suspension setup is determined to be optimal, the suspension performance under load can be recorded and used to set up the same car when it returns to a specific track or to become a base point for another car in development, thereby shortening development time.
Of course, when a car is supported on an elevated platform according to the invention, it is possible to unload its suspension if desired. For example, we have found it easy to put a scissors jack on the platform and jack up a wheel to change a tire.
It will be understood that, while presently preferred embodiments of the invention have been illustrated and described, the invention is not limited thereto, but may be otherwise variously embodied within the scope of the following claims. It will also be understood that the method claims are not intended to be limited to the particular sequence in which the method steps are listed therein, unless specifically stated therein or required by description set forth in the steps. | A system for servicing a racing car or other car at a track, other race course, or similar destination employs an open platform for supporting the car by its tires in a horizontal position. The platform supports the car, and is itself supported by a crawler, in a carrier vehicle, for example a truck or trailer, when the carrier vehicle is transporting the car. The crawler and platform are also used to unload and load the car from and into the carrier vehicle. To unload the car at the destination, the crawler, with the platform and car on it, is driven out of the carrier vehicle and onto the ground. Next, the platform is elevated by extending its legs so that it rises off, is spaced from, and straddles the crawler. Then the crawler is driven out from under the platform. Then the platform is lowered to the ground, where it is used as a lift to elevate the car so that its undercarriage may be accessed. The platform may also be used to tune the chassis of the car. The chassis tuning may include manipulating the chassis to a static position which emulates an instantaneous position of the car on the race course. The carrier, platform, and car may be loaded back into the carrier vehicle by the reverse procedure. | 1 |
CROSS-REFERENCE TO RELATED APPLICATIONS
The present application claims priority under 35 U.S.C. 119 to Korean Patent Application No. 10-2010-0136066, filed on Dec. 27, 2010, which is hereby incorporated by reference in its entirety.
BACKGROUND
The present disclosure relates to a power supply device.
In general, in order to use an electrical appliance such as a copying machine, a video recorder, a microwave oven, a dish washer, a cell phone charger, a computer, a monitor, a printer, a facsimile, and a washing machine in a home or an office, commercial power is supplied via connecting a plug, wired to the electrical appliance, to a wall outlet installed at the wall of a building or a multi tap extending from the wall outlet.
Moreover, while the electrical appliance is installed, the plug of an electrical appliance connected to a wall outlet installed at the wall of a building or a multi tap typically maintains a constant state of being connected to each other, so that commercial power is continuously supplied regardless of its use. When commercial power is constantly supplied through the plug of an electrical appliance connected to a wall outlet, the time required for standing by a certain function in a power off state takes a larger part of a total usage time than the time required for performing an original function of the electrical appliance. Therefore, the consumption of power vampire, which plays an important role in determining an energy efficiency rating of an electrical appliance, is excessively high.
In order to completely prevent the consumption of power vampire in an electrical appliance, a user may directly separate the plug of an electrical appliance from a wall outlet or a multi tap or may turn off a power switch in each power outlet of a multi tap. As a result, a commercial power (i.e., a main power) supplied to the electrical appliance is completely cut off. However, this is very cumbersome. Due to this reason, the complete standby power off is not widely used.
Additionally, as a commercial power (i.e., a main power) is constantly supplied to an electrical appliance through a plug connected to a wall outlet, components of the electrical appliance become deteriorated thereby reducing its lifecycle. Also, when an over current occurs due to a bolt of lightning, it occasionally flows into the electrical appliance along its power line to damage the electrical appliance.
Furthermore, various devices, which cut off Power Vampire when it is determined by recognizing power consumption that power is off, have been developed and mounted on an electrical appliance. However, in such a case, the electrical appliance is not turned on when a remote controller is used for a certain operation. Thus, a user may personally turn on a power switch mounted on the electrical appliance and this causes inconvenience.
Moreover, if a commercial power (i.e., a main power) supplied to an electrical appliance is cut off, its timer mode becomes useless.
SUMMARY
Embodiments provide a power supply device having a power vampire reduction circuit.
Embodiments also provide a power supply device having improved reliability by detecting an input state of power and reducing standby power automatically.
In one embodiment, a power supply device includes: an AC power output unit storing and outputting an AC power; a rectifier unit rectifying an output of the AC power output unit; a DC output unit outputting an output from the rectifier unit as a DC power; and a standby power reduction unit detecting a signal regarding whether the AC power is inputted or not and discharging a standby power stored in the AC power output unit in response to the detected signal.
The details of one or more embodiments are set forth in the accompanying drawings and the description below. Other features will be apparent from the description and drawings, and from the claims.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a circuit diagram illustrating a power supply device according to a first embodiment.
FIG. 2 is a view of the standby power reduction unit of FIG. 1 .
FIG. 3 is a circuit diagram of the standby power reduction unit of FIG. 1 .
FIG. 4 is a circuit diagram of a power supply device according to a second embodiment.
FIG. 5 is a circuit diagram of the standby power reduction unit of FIG. 4 .
FIG. 6 is a circuit diagram of a standby power reduction unit according to a third embodiment.
FIG. 7 is a circuit diagram of a standby power reduction unit according to a fourth embodiment.
FIG. 8 is a circuit: diagram of a standby power reduction unit according to a fifth embodiment.
DETAILED DESCRIPTION OF THE EMBODIMENTS
Reference will now be made in detail to the embodiments of the present disclosure, examples of which are illustrated in the accompanying drawings.
FIG. 1 is a circuit diagram illustrating a power supply device according to a first embodiment.
Referring to FIG. 1 , the power supply device 100 includes a power unit 101 , an AC power output unit 102 , a rectifier unit 103 , a Power Factor Correction (PFC) unit 104 , a DC power output unit 105 , a standby unit 106 , and a standby power reduction unit 110 .
The AC power output unit 102 stores and outputs an AC power inputted from the power unit 101 . The AC power includes commercial power. The AC power input unit 102 includes a capacitor Cx, for example. The capacitor Cx is connected in parallel to the both terminals of the power unit 101 and charges and discharges an AC power. As another example, the AC power output unit 102 may include a filter but is not limited thereto.
The rectifier unit 103 rectifies and outputs an AC power outputted from the AC power output unit 102 . The rectifier unit 103 may include a bridge diode and wave-rectifies and outputs an AC power.
An input capacitor Cin is connected to the both output terminals of the rectifier unit 103 and removes a ripple of a DC power outputted from the rectifier unit 103 and outputs the DC power to the PFC unit 104 . The PFC unit 104 may include a line filter and a capacitor device but is not limited thereto.
The PFC unit 104 improves a power factor of the voltage rectified by the rectifier unit 103 , converts the rectified voltage into a DC voltage, and outputs the DC voltage. The DC output unit 105 converts an output voltage of the PFC unit 104 into a DC voltage necessary for a load and outputs the DC voltage. The DC output unit 105 may include a DC converter or a transformer.
The standby unit 106 receives an input power of the PFC unit 104 , outputs the input power as a standby power, and controls an operation status of a system in response to an external control signal.
The standby power reduction unit 110 is connected to at least one of the both terminals of the power unit 101 , detects whether an inputted power V AC — L and V AC — N is supplied, is turned off (i.e., a n operating mode) when it is detected that the AC power is more than a predetermined level (i.e., an operating voltage), and is turned on (i.e., a standby mode) when it is detected that the AC power is not more than the predetermined level (i.e., an operating voltage).
If an AC power of the standby power reduction unit 110 is not supplied, power is not supplied to the power unit 101 . At this point, the standby power reduction unit 110 provides a discharge path for lowering a power (hereinafter, referred as a standby power) stored in the AC power output unit 102 to be lower than a predetermined voltage within a predetermined time.
The standby power reduction unit 110 is connected to the both terminals of the AC power output 102 and discharges a standby power of the AC power output unit 102 to a ground terminal.
The standby power reduction unit 110 operates by receiving a bias voltage from the standby unit 106 or the external and the bias voltage may be supplied while the standby power is reduced even if the power of the power unit 101 is off.
The standby power reduction unit 110 is turned on when the AC power is not supplied and provides a discharge path of the stored standby power, thereby reducing the standby power stored in the AC power output unit 102 for a predetermined time. Accordingly, the standby power stored in the AC power output unit 102 may be lowered than a predetermined voltage for a predetermined time, so that damages to a device or a user due to a high AC voltage may be prevented. The standby power reduction unit 110 may satisfy a safety standard that energy stored in the AC power output unit 102 should be lower than about 60 V within 2 seconds.
Referring to FIG. 2 , the standby power reduction unit 110 includes an AC power detection unit 111 , a bias power supply unit 113 , a standby power rectifier unit 114 , and a discharge unit 115 .
The AC power detection unit 111 is connected to a second line V AC — N among the both terminals of the power unit 101 and detects a power S 1 applied to the second line V AC — N of the power unit 101 . As another example, the AC power detection unit 111 may be connected to a first line V AC — L but is not limited thereto. The first line V AC — L may be a positive polarity terminal and the first line V AC — N may be a negative polarity terminal.
The AC power detection unit 111 turns off an operation of the bias voltage supply unit 113 in a power mode and turns on an operation of the bias voltage supply unit 113 in a standby mode. That is, the AC power detection unit 111 controls an operating voltage of the bias voltage supply unit 113 according to whether power is supplied or not.
The bias voltage supply unit 113 controls an output of a bias voltage according to an operation status of the AC power detection unit 111 and outputs a bias voltage to the standby unit 106 in a standby mode.
The discharge unit 115 is turned on by a voltage of the standby unit 106 and the standby power rectifier unit 114 rectifies a standby power stored in the AC power output unit 102 . The standby power rectifier unit 114 is connected to the both terminals of the AC power output unit 102 and rectifies and outputs the standby powers P 1 and P 2 applied to one of the both terminals of the AC power output unit 102 .
The discharge unit 115 outputs the standby power S 3 rectified by the standby power rectifier unit 114 to the ground terminal through conduction. Accordingly, the discharge unit 115 provides a discharge path of a standby power in a standby mode.
FIG. 3 is a circuit diagram of the standby power reduction unit of FIG. 1 .
Referring to FIGS. 2 and 3 , the AC power detection unit 111 is connected to a first line V AC — N to which an AC power is applied and receives an AC power through the first line V AC — N . The first line V AC — N may be a negative polarity terminal
The AC power detection unit 111 includes an operating voltage detection circuit 111 A and a comparison device 111 B. The operating voltage detection circuit 111 A detects a level of the AC power and then, outputs it as an operating voltage of the comparison device 111 B. The comparison device 111 B is conducted or outputs a reference voltage according to an operating voltage level of the operating voltage detection circuit 111 A.
The operating voltage detection circuit 111 A includes a first capacitor C 1 , a third diode D 3 , a fourth diode D 4 , first to third resistors R 1 , R 2 , and R 3 , second and third capacitors C 2 and C 3 , and a fourth capacitor C 4 . Here, the first capacitor C 1 and the third resistor R 3 constitute a charge/discharge circuit. The third diode D 3 is used for protection. The second and third capacitors C 2 and C 3 are a ripple removing circuit and are connected to the first and second resistors R 1 and R 2 to constitute a differential circuit or a low pass filter. The first and second resistors R 1 and R 2 constitute a voltage divider circuit and the fourth diode D 4 is connected to a reverse current path.
The first capacitor C 1 is connected to a second line V AC — N . An anode of the third diode D 3 and a cathode of the fourth diode D 4 are connected to the first capacitor. C 1 . An anode of the third diode D 4 is connected to a ground terminal.
The first resistor R 1 and the second resistor R 2 are connected in series to the third diode D 3 . The second capacitor C 2 is connected in parallel to between the first resistor R 1 and the second resistor R 2 . The other terminal of the second capacitor C 3 is grounded.
The third resistor R 3 is connected in parallel to the second resistor R 2 . The third capacitor C 3 is connected in parallel to between the third resistor R 3 and the second resistor R 2 . The other terminal of the third capacitor C 3 is grounded. A reference terminal Vref of the comparison device 111 B is connected to a connection node between the second resistor R 2 and the third resistor R 3 . In the comparison device 111 B, a second terminal (−) is connected to the ground terminal and the first terminal (+) is connected to the bias voltage supply unit 113 . The fourth capacitor C 4 is connected to between the reference terminal and the first polarity terminal of the comparison device 111 B.
The operating voltage detection circuit 111 A charges an inputted current IAC on the first capacitor C 1 and discharges the current I AC through the resistor RI, the second capacitor C 2 , the second resistor R 2 , and the third capacitor C 3 . The operating voltage detection circuit 111 A detects an operating voltage of the comparison terminal 111 B.
An operating voltage divided by the second resistor R 2 and the third resistor R 3 is applied to the reference terminal of the comparison device 111 B. The comparison device 111 B outputs a low output VKA to the second terminal (+) when the operating voltage higher than an internal reference voltage is applied and an output VKA of the second terminal (+) is raised when the operating voltage lower than the internal reference voltage is applied.
The comparison device 111 B as an integrated device includes a shunt regulator or a comparator. The comparison device 111 B compares an input operating voltage with an internal reference voltage. The comparison device 111 B outputs a high signal if the input operating voltage is lower than the internal reference voltage and outputs a low signal if not. Here, the comparison device 111 B outputs a low signal in a power mode and outputs a high signal in a standby mode.
If the comparison device 111 B is a shunt regulator, the reference terminal is connected to the resistors R 2 and R 3 , an anode terminal is connected to the ground terminal, and a cathode terminal is connected to the bias power supply unit 113 .
The bias voltage supply unit 113 includes a first switching device Q 1 . A bias voltage VCC inputted from a standby unit is applied to a gate terminal and a drain terminal of the first switching device Q 1 . The first switching device Q 1 is turned on and outputs the bias voltage VCC when a high signal is outputted from the AC power output unit 111 . The first switching device Q 1 is turned off and may not output the bias voltage VCC when a low signal is outputted from the AC power output unit 111 .
The first switching device Q 1 is a MOS transistor, for example, a Metal oxide Semiconductor Field-Effect Transistor (MOSFET). As another example, the first switching device Q 1 may be a bipolar junction transistor.
An output signal S 2 of the bias voltage supply unit 113 is inputted to the discharge unit 115 . The discharge unit 115 includes a second switching device Q 2 , which is turned on/off according to an output signal S 2 of the bias voltage supply unit 113 . In the second switching device Q 2 , voltage divider resistors R 7 and R 8 are connected to a gate terminal and an output S 2 of the bias voltage supply unit 113 is inputted to the gate terminal; a discharge resistor RX is connected to a drain terminal and an output S 3 of the standby power rectifier unit 114 is inputted to the discharge resistor RX; and a source terminal is grounded. The second switching device Q 2 may be a MOS transistor, for example, a MOSFET. As another example, the second switching device Q 2 may be a bipolar junction transistor.
Since the standby power rectify unit 114 includes diodes D 1 and D 2 , it operates when a standby power has a positive or negative polarity.
When the first switching device Q 1 of the bias voltage supply unit 113 is turned on, the second switching device Q 2 is turned on. When the second switching device Q 2 is turned on, an output S 3 of the standby power rectify unit 114 is discharged to the ground terminal.
Here, each device of the standby power reduction unit 110 affects a time from the start of a standby mode to the start of an operation of the discharge resistor RX. A resistance value of the discharge resistor RX determines a time from the start of an operation of the second switching device Q 2 to the start of a voltage drop below a predetermined value. Accordingly, a resistance value of the discharge resistor RX is reduced to make a discharge time of a standby power faster.
FIGS. 4 and 5 are detailed configuration of a power supply device and a standby power reduction unit according to a second embodiment.
Referring to FIG. 4 , the standby power reduction unit 110 receives a standby power through an output terminal of the rectifier unit 103 , i.e., a positive polarity terminal, and then discharges it. Without the additional standby power rectifier unit of FIG. 2 , the rectified power Vin of the rectifier unit 103 is discharged.
The standby power reduction 110 operates in a standby mode and the standby power stored in the AC power output unit is applied to the standby power reduction unit 110 through the rectifier unit 103 and then is discharged. Additionally, the power stored in the input capacitor Cin connected to the output terminal of the rectifier unit 103 may be applied to the standby power reduction unit 110 and then may be discharged.
The standby power reduction unit 110 may discharge a voltage of the capacitor Cx of the AC power output unit 102 and a voltage of the input capacitor Cin connected to the output terminal of the rectifier unit 103 to be less than a predetermined level and may provide a discharge path in a standby mode.
FIG. 5 is a circuit diagram of the standby power reduction unit of FIG. 4 . Like FIGS. 4 and 5 , since a standby power is discharged through a path of the rectifier unit 103 , the first and second diodes of the standby power rectifier unit shown in FIG. 3 may not be required.
FIG. 6 is a circuit diagram of a standby power reduction unit according to a third embodiment.
Referring to FIG. 6 , the standby power reduction unit connects the resistor R 10 instead of the diode D 4 of FIG. 3 to a reverse current path connected to the first capacitor C 1 , thereby allowing a reverse current of the first capacitor C 1 to flow through resistance.
FIG. 7 is a circuit diagram of a standby power reduction unit according to a fourth embodiment.
Referring to FIG. 7 , the AC power detection unit 111 of the standby power reduction unit includes an operating voltage detection circuit 11 A and a switching device Q 3 . The third switching device Q 3 may be a MOSFET and, as another example, may be a bipolar junction transistor.
When the third switching device Q 3 is in a standby mode, a low signal is applied to a gate terminal and a bias voltage Vcc is applied to a base terminal of the first switching device Q 1 , so that the third switching device Q 3 operates. Accordingly, the first switching device Q 1 operates through conduction. Due to an operation of the first switching device Q 1 , the second switching device Q 2 is conducted, thereby discharging a standby power to a ground terminal through the discharge resistor Rx connected to a drain terminal.
FIG. 8 is a circuit diagram of a standby power reduction unit according to a fifth embodiment.
Referring to FIG. 8 , the AC power detection unit 111 of the standby power reduction unit is connected to the AC power V AC — L of a positive polarity. That is, the AC power detection unit 111 may be selectively connected to a positive polarity or a negative polarity of the power unit but is not limited thereto.
The standby power reduction unit according to embodiments may be applied to image devices such as a plasma display panel (PDP) TV, a liquid crystal display (LCD) TV, a light emitting diode (LED) TV, and a monitor and also various lighting devices.
According to embodiments, a relay may not be required.
According to embodiments, a relay having a large size is not required, so that electronic products such as TVs or monitors may have a thin thickness.
According to embodiments, a reliable standby power reduction device may be provided.
Although embodiments have been described with reference to a number of illustrative embodiments thereof, it should be understood that numerous other modifications and embodiments can be devised by those skilled in the art that will fall within the spirit and scope of the principles of this disclosure. More particularly, various variations and modifications are possible in the component parts and/or arrangements of the subject combination arrangement within the scope of the disclosure, the drawings and the appended claims. In addition to variations and modifications in the component parts and/or arrangements, alternative uses will also be apparent to those skilled in the art. | A power supply device is provided. The power supply device includes: an AC power output unit storing and outputting an AC power; a rectifier unit rectifying an output of the AC power output unit; a DC output unit outputting an output from the rectifier unit as a DC power; and a standby power reduction unit detecting a signal regarding whether the AC power is inputted or not and discharging a standby power stored in the AC power output unit in response to the detected signal. | 8 |
TECHNICAL FIELD
The present invention relates generally to a control system to adapt a sewing machine for semi-automatic operation. More particularly, this invention is directed to an adaptive sewing machine control system incorporating a microprocessor controller in combination with a stitch counter, an edge sensor and stitch length control apparatus to achieve more precise seam lengths and end points.
BACKGROUND OF THE INVENTION
In the sewn goods industry, where various sections of material are sewn together to fabricate products, precise seam lengths and end points are often necessary for proper appearance and function of the finished products. For example, the top stitch seam of a shirt collar must closely follow the contour of the collar and terminate at a precise point which matches the opposite collar. Accurate seam lengths must similarly be maintained in the construction of shoes when sewing together vamps and quarter pieces to achieve strength as well as pleasing appearance. Achieving consistently accurate seam lengths and end points at high rates of production has, however, been a long standing problem in the industry.
Microprocessor controllers have been developed which convert manually operated sewing machines into semi-automatic sewing systems. U.S. Pat. Nos. 4,108,090; 4,104,976; 4,100,865; and 4,092,937, assigned to the Singer Company are representative of such devices. Each of those patents discloses a programmable sewing machine with three operational modes: manual, teach and auto. Control parameters are programmed into the system for subsequent control of the sewing machine in the auto mode. Those microprocessors control all sewing machine functions such as sewing speed, presser foot position, thread trimmer, reverse sew mechanism and the number of stitches sewn in each individual seam. Accurate control of seam lengths is one of the important aspects of those systems.
U.S. Pat. No. 4,404,919 issued Sept. 20, 1983, entitled "Control System for Providing Stitch Length Control of a Sewing Machine", assigned to assignee describes a microprocessor controlled sewing system which improves upon the seam length accuracy of those systems. The system disclosed in U.S. Pat. No. 4,404,919 controls seam length accuracy using a combination of stitch counting, edge detection and stitch length control techniques. Control of seam lengths and end points is achieved in the system by initiating countdown of a variable number of final whole and partial stitches responsive to detection of the end of the material being sewn by sensors located ahead of the needle. In dependence upon the amount of the stitch which has been sewn upon edge detection, the microprocessor issues a signal to position the reverse sew mechanism of the sewing machine while the last stitch is being formed to reduce the length of the last stitch to a desired percentage of the normal stitch length and thus improve the accuracy of the seam end point.
Though ideally the time delay between the microprocessor issuing the signal to activate the reverse sew mechanism and the actual movement of the mechanism to reduce the length of the last stitch is zero, in practice, that time delay is typically in the range of 10 to 40 milliseconds. Were the sewing machine operated so that stitches are formed continuously during a complete revolution of the sewing machine motor, that delay could be easily compensated for and the desired results achieved be issuing the signal to activate the reverse sew mechanism, for example, 10 to 40 milliseconds early. However, the formation of stitches in a typical sewing machine occurs in an intermittent manner, each stitch being formed during approximately 120 degrees of revolution for each complete revolution of the motor and no stitch formation occurring in the remaining 240 degrees of revolution. The combination of retraction time delay and intermittent feed often causes the length of the last stitch to vary from the desired length.
A need has arisen, therefore, for an improved adaptive sewing machine control system which includes a stitch length control technique which compensates for the activation time delay of the reverse mechanism and intermittent feed characteristics of the sewing machine to accurately reduce the length of the last stitch.
SUMMARY OF INVENTION
The present invention comprises an adaptive sewing machine control system which substantially improves seam length accuracy by dynamically reducing and accurately controlling the length of the last stitch in the seam.
In accordance with the invention, there is provided a system including a microprocessor controller which can be programmed with or taught a sequence of sewing operations by the operator in one mode for automatically controlling the machine during subsequent sewing of similar pieces of the same or different sizes in another mode. The semi-automatic system uses a combination of stitch counting and material edge detection techniques together with techniques for varying the length of the last stitch sewn to achieve more accurate seam length and end point control.
More specifically, this invention comprises a microprocessor-based control system for an industrial sewing machine. The system has manual, teach and auto modes of operation. In the preferred embodiment, one or more sensors are mounted in front of the presser foot for monitoring edge conditions of the material at the end of each seam. In the teach mode, operating parameters are programmed into the controller by the operator. For each seam, the number of whole and partial stitches x sewn after the desired status change in the sensors are recorded along with sewing machine and auxiliary control inputs. In the auto mode, the number of stitches sewn in each seam is monitored until the characteristic sensor pattern indicating edge detection is seen, at which time x additional stitches are sewn to complete the seam. The amount of stitch completion at the time of detection of the material edge is monitored and the reverse sew mechanism of the sewing machine is actuated at a selected point taking into account the activation time delay of the reverse sew mechanism and the feed characteristics of the sewing machine to control the length of the last seam stitch to the desired length.
BRIEF DESCRIPTION OF DRAWINGS
A more complete understanding of the invention can be had by reference to the following detailed description taken in conjunction with the accompanying Drawing, in which:
FIG. 1 is a perspective view of a programmable sewing system incorporating the invention;
FIG. 2 is a front view illustrating placement of the edge sensor relative to the sewing needle;
FIG. 3 is a sectional view taken along lines 3--3 of FIG. 2 in the direction of the arrows;
FIG. 4 is an end view of the sewing system illustrating the automatic control apparatus of the sewing machine reverse mechanism;
FIG. 5 is a graph illustrating the degrees of rotation of a sewing machine motor plotted against the length of a resulting stitch; and
FIG. 6 is a flowchart of the technique of the present invention to dynamically reduce the length of the last stitch to a desired percentage of the normal stitch length.
DETAILED DESCRIPTION OF THE INVENTION
Referring now to the Drawing, wherein like reference numerals designate like or corresponding parts throughout, FIG. 1 illustrates a semi-automatic sewing system 10 incorporating the invention. System 10 is a microprocessor-based system adapted to extend the capabilities of a sewing machine to enable the operator to perform sewing procedures on a manual or semi-automatic basis.
System 10 includes a conventional sewing machine 12 mounted on a work stand 14 consisting of a table top 16 supported by four legs 18. Sewing machine 12, which is of conventional construction, includes a spool 20 containing a supply of thread for stitching by a reciprocable needle 22 to form a seam in one or more pieces of material. Surrounding needle 22 is a vertically movable presser foot 24 for cooperation with movable feed dogs (not shown) positioned within table top 16 for feeding material past the needle.
A number of standard controls are associated with sewing machine 12 for use by the operator in controlling its functions. A handwheel 26 is attached to the drive shaft (not shown) of machine 12 for manually positioning needle 22 in the desired vertical position. Sewing speed is controlled by a speed sensor 15 which is actuated by a foot treadle 28, which functions as an accelerator. Vertical positioning of presser foot 24 can be controlled by heel pressure on foot treadle 28 which closes a switch 19 in speed sensor 15, which in turn causes the presser foot lift actuator 30 to operate. A leg switch 32 is provided for controlling the sewing direction of machine 12 by causing operation of a reverse sew mechanism 17. The reverse sew mechanism 17 is positioned by a stepper motor 21 which can position the reverse sew mechanism 17 in various positions to vary the length of the stitch formed by the sewing machine 12. The reverse sew mechanism 17 and stepper motor 21 are referred to in combination as the stitch length variance mechanism. A toe switch 34 located adjacent to foot treadle 28 controls a conventional thread trimmer (not shown) disposed underneath the throat plate 36 of machine 12. Foot switch 38 on the other side of foot treadle 28 comprises a one-stitch switch for directing machine 12 to sew a single stitch.
Sewing machine 12 and its associated manual controls are of substantially conventional construction, and may be obtained from several commercial sources, e.g., Singer, Union Special, Pfaff, Consew, Juki, Columbia, Brother or Durkopp Companies.
In addition to the basic sewing machine 12 and its manual controls, system 10 includes several components for adapting the sewing machine for semi-automatic operation. One or more sensors 40 are mounted in laterally spaced-apart relationship in front of needle 22 and presser foot 24. A drive unit 42 comprising a variable speed direct drive motor, sensors for stitch counting and an electromagnetic brake for positioning of needle 22, is attached to the drive shaft of sewing machine 12. A main control panel 44 supported on a bracket 46 is provided above one corner of work stand 14. A pneumatic control chassis 48 containing an air regulator, filter and lubricator for the sewing machine control sensors, pneumatic actuators and other elements of system 10 is provided on one side of work stand 14. All of these components are of known construction and are similar to those shown in U.S. Pat. Nos. 4,108,090; 4,104,976; 4,100,865 and 4,092,937, the disclosures of which are incorporated herein by reference.
A controller chassis 50 is located on the opposite side of work stand 14 for housing the electronic components of system 10. Chassis 50 includes a microprocessor controller 51, appropriate circuitry for receiving signals from sensors and carrying control signals to actuators, and a power module for providing electrical power at the proper voltage levels to the various elements of system 10. The microprocessor controller 51 may comprise a Zilog Model Z-80 microprocessor or any suitable unit having a read only memory (ROM) and random access memory (RAM) of adequate storage capacities. An auxiliary control panel 52 is mounted for sliding movement in one end of chassis 50.
Referring now to FIGS. 2 and 3, further details of edge sensors 40 and their cooperation with needle 22 can be seen. Sensors 40 may be mounted directly on the housing of sewing machine 12, or supported by other suitable means. Each sensor 40 comprises a lamp/photosensor which projects a spot of light 40a onto a reflective tape strip 54 on throat plate 36. The status of each sensor 40 is either "on" or "off" depending upon whether or not the light beam thereof is interrupted, such as by passage of the trailing edge or discontinuity of the particular piece of material.
Sensors 40 are positioned in mutually spaced relationship ahead of needle 22 and sewing machine 12. The condition of at least one sensor 40 changes as the trailing material edge passes thereunder to indicate approach of the seam end point. Sensors such as the Model 10-0672-02 available from Clinton Industries of Carlstadt, N.J., have been found satisfactory as sensors 40, however, infrared sensors and emitters, or pneumatic ports in combination with back pressure sensors could also be utilized, if desired.
Circuitry is provided in chassis 50 which detects the output of sensors 40 to generate electrical signals representative of the material edge. Controller 51 is responsive to such edge detection for allowing a selected number of stitches to be sewn after the edge detection. Controller 51 also determines the amount of the currently sewn stitch which has been completed at edge detection in response to the sewing machine motor rotation. Depending upon the amount of the stitch sewn at edge detection and taking into account the activation time delay of the stitch length variance mechanism and the interval of motor rotation during which a seam is formed, controller 51 controls the stitch length variance mechanism of the machine to vary the length of the last stitch sewn to a desired percentage of the normal stitch length.
The present system may first be programmed in a teach mode and thereafter operated in an auto mode. The system may be taught in the teach mode to sew x stitches after the material edge is detected where x can be a combination of whole and partial stitches. Thereafter, when the system is operated in the auto mode, the edge of the material will be automatically detected by the sensor and the machine will then automatically sew x stitches before terminating the seam. In this manner, automatic operation of the system is provided to increase the speed and accuracy of the system without human intervention. The present system operates in essentially the same manner as the system described in U.S. Pat. No. 4,404,919, the disclosure of which is incorporated herein by reference, with additional improvement and accuracy being provided by the present invention as will be subsequently described.
In operation of the system thus described, as a seam is sewn by the machine, the number of stitches from the starting point are counted by the encoder within drive unit 42. The reflective tape 54 will be covered by the material and the beams of the sensors 40 are blocked by the material. When the edge of the material moves past the reflective tape 54, the sensor beams are reflected from the reflective tape 54 and sensed. This provides the system with an indication of the location of the edge of the material so that the seam length can be stopped at a given distance from the material edge. The system is originally taught by the operator to sew a given number of whole and partial stitches x in a seam after the edge of the material is detected. When the operation is repeated in the automatic sewing mode, the system will sew until the edge is detected, and will then sew x stitches before terminating the seam. Depending upon the percentage of the stitch which has been sewn at the time of detection of the material edge, the reverse sew mechanism is positioned to vary the length of the last stitch sewn to provide increased accuracy to the seam termination.
Referring to FIG. 4, an enlarged view of the reverse sew assembly is illustrated. A stepper motor 21 is actuated to pivot reverse sew mechanism 17 about a pivot point 23. Mechanism 17 is illustrated in the solid line position in its normal operating position in the forward sew mode. When mechanism 17 is fully activated by stepper motor 21 to position 17', the sewing machine will form one normal length stitch in the reverse direction. Positioning mechanism 17 at position 17" will result in a reduced length stitch being sewn in the forward direction. Therefore, stepper motor 21 can be used to vary the stitch length produced. Mechanism 17 and stepper motor 21 form a stitch length variance mechanism which is controlled by the microprocessor to control the length of the last stitch in each seam.
It will be understood that other techniques may be used to vary the length of the stitch. For example, the material feeding mechanism, known as feed dogs, may be retracted by an air cylinder while the last stitch is being formed. The air cylinder may be operated by a solenoid control actuated by the microprocessor, in order to accurately vary the length of the last stitch formed.
FIG. 5 illustrates the feeding characteristics of a typical sewing machine such as shown in FIG. 1 wherein stitch formation occurred in an intermittent manner over approximately 120 degrees of the motor rotation. As shown in FIG. 5, the stitch is not begun until the motor has rotated approximately 60 degrees at DSTART. The stitch is then formed until it is completed at DSTOP after the sewing machine motor has completed approximately 180 degrees rotation. The last 180 degree rotation of the sewing machine motor enables the machine to ready for the formation of the next stitch. The interval of the motor rotation over which stitch formation occurs is stored by controller 51 to enable the percentage of the stitch completed at edge detection to be computed for each seam.
If the time delay was zero between controller 51 issuing a signal to activate reverse sew mechanism 17 and the actual actuation of reverse sew mechanism 17, the length of the last stitch could be thus accurately reduced to the desired length regardless of the point in the formation of the last stitch at which the microprocessor signalled activation of reverse sew mechanism 17. In practice, however, an activation time delay, typically in the 10 to 40 millisecond range, will exist between the issuance of the signal and the actual actuation of reverse sew mechanism 17. That time delay coupled with the intermittent feed characteristics of the sewing machine, described above with reference to FIG. 5, causes the length of the last stitch to vary from the desired length.
For example, if the speed of the sewing machine is 300 revolutions per minute at the time the last stitch is initiated, 200 milliseconds are required for one revolution of the sewing machine motor. Because a stitch is actually formed during only one-third of a motor revolution, stitch formation occurs over an interval of approximately 67 milliseconds. Assume that the activation delay time associated with the reverse mechanism is 30 milliseconds, or approximately 50% of stitch formation time. Thus, if controller 51 issues a command to actuate the reverse mechanism when 10% of the last stitch has been formed, the system will actually produce a stitch approximately 60% of a normal stitch length because of the activation time delay. Similarly, if the actuation signal is issued at the start of the last stitch, the stitch will be 50% of a normal stitch length and if issued after 50% of the last stitch has been formed, the last stitch will be 100% of a normal stitch length. Thus in this example, the last stitch will always be 50 to 100% of a normal stitch length, depending upon when the signal is issued.
The system of the present invention improves upon the operation of the system of U.S. Pat. No. 4,404,919 by issuing the signal to actuate the reverse mechanism at a selected point in the motor revolution which compensates for the activation time delay and intermittent feed characteristics and thereby produces more accurate seam margins. FIG. 6 is a flow chart illustrating the technique of the present invention for determining the motor angle at which a signal to actuate of the reverse mechanism should be issued to compensate for those factors. The steps are implemented by suitable programming of controller 51. The program is suitable for adaptation to the Zilog Z-80 microprocessor and may be written into Z-80 assembly language in a manner known to the art.
In accordance with the present invention, once the start of the last stitch in the seam is sensed at 60, the machine speed in revolutions per minute is determined at 62. At 64 the number of degrees of motor rotation taken during the activation time delay is then computed by the formula: 360* (SPM*RT)/60, where SPM is the speed of the motor while the last stitch is formed in revolutions per minute and RT is the activation time delay in seconds. Before the start of the sewing operation, the machine operator measures the activation time delay and enters that time as data to controller 51 by means of operator control panel 52. The operator also inputs to controller 51, data defining the motor angles at which stitch formation begins and ends. This data is stored in the memory associated with the microprocessor of controller 51. The motor angle of rotation at which the signal to actuate reverse mechanism 17 should be issued to reduce the length of the last stitch to x% of the normal stitch length is computed at 68 using the formula: (B-A) +((x/100)* (C-B)), where A is the number of degrees of motor rotation taken during the activation time delay, B is the motor angle at the start of the stitch and C is the motor angle at the end of the stitch. A determination of whether that motor angle of rotation has been reached is made at 70. If it has, a command to activate the reverse sew mechanism is issued at 72 otherwise, sewing continues at 74. If the result of the calculation of the motor angle is negative, the command to activate the reverse sew mechanism is issued in the stitch preceding the last stitch at a motor angle equal to that angle plus 360 degrees. This technique assures that the last stitch can be varied from 0 to 100% of the normal stitch length and accurate seam margins are thereby produced.
Whereas the present invention has been described with respect to specific embodiments thereof, it will be understood that various changes and modifications will be suggested to one skilled in the art, and it is intended to encompass such changes and modifications as fall within the scope of the appended claims. | An adaptive semi-automatic sewing system (10) comprises a sewing machine (12), a drive unit (42) including a variable speed direct drive motor and encoder for counting stitches sewn and for sensing the rotation of the motor, at least one material edge sensor (40) mounted ahead of the needle (22) of the sewing machine, and a microprocessor controller (51) coupled to the sewing machine controls. Accurate control of seam lengths and end points is achieved by initiating countdown of a variable number of final stitches responsive to detection of the material edge by the sensors (40). The amount of stitch completion at the time of detection of the material edge is monitored and a stitch length variance mechanism (17) is actuated at a selected angle of motor rotation taking into account the time delay of the stitch length variance mechanism and the feed characteristics of sewing machine (12) to precisely control the length of the last stitch sewn to improve the accuracy of the seam end point. | 3 |
STATEMENT OF GOVERNMENT INTEREST
The invention described herein may be manufactured and used by or for the Government of the United States of America for governmental purposes without the payment of any royalities thereon or therefor.
BACKGROUND OF THE INVENTION
This invention relates to valves, and more particularly to power-operated valve and pump apparatus for flooding and evacuating sea water from compartments of ships.
Efficient disposal of excess or unwanted water, which leaks or is admitted into waterborne vessels, has historically been a problem of great concern. Sea water can enter a ship's compartments in a "passive" manner, e.g. by leakage or flooding (as disclosed in the U.S. Pat. Nos. 551,473; 706,561; and 1,127,648 to Perkins, Holland and Lake, respectively) or in an "active" manner, e.g., by pumping (as disclosed in the U.S. Pat. Nos. 1,796,200, 3,242,613 to Grieshaver and Schwartz, respectively).
At present the two most widely used methods of water evacuation involve either removal of the water from a compartment by centrifugal pumping, or by sealing a compartment and pumping of compressed air into it to "blow out" the water. There are disadvantages, however, attendant with conventional centrifugal pumping methods which make their use extremely undesirable. These methods require, for example, use of extremely expensive machinery and extensive amounts of interconnecting piping. Related to this is the great loss of energy (power consumption) due to frictional losses in the piping system. And in the "blow out" method, a great amount of non-recoverable heat is generated as a result of the air compression, and the pumped air is heated sufficiently to require extensive insulation of the air pipes. This extra insulation not only increases installation costs, but also adds extra weight and maintenance.
SUMMARY OF THE INVENTION
Accordingly, the present invention provides for a valve and pump assembly disposed in an opening in a floodable compartment of a ship. The valve portion of the assembly is mounted for reciprocatory translation into blocking and unblocking positions and employs remotely powered hydraulic positioners to effect the translatory motion. The pump portion of the assembly is housed within, and concentrically carried by, the assembly valve portion. In one embodiment, the pump portion includes a rotatable impeller connected by a splined shaft arrangement to a reversible source of power for rotatably driving the impeller. Operation involves actuation of the hydraulic positioners to cause displacement of the valve portion relative to the opening from a blocking position to either a partially extended, unblocking position or a fully extended unblocking position (for ballasting or for deballasting, respectively) and then actuation of the impeller power source to cause rotation of the impeller. In this way, when the valve portion is in its ballasting position, rotation of the impeller in a first direction assists the entrance of sea water into the compartment through the opening, and when the valve portion is in its deballasting position, rotation of the impeller in a reversed direction will assist expulsion of the sea water from the compartment through the opening. In a second embodiment, the pump portion includes a rotatable centrifugal impeller connected to a source of power which drives the impeller. Operation of the second embodiment contemplates pumping only for deballasting which effects expulsion of water from the compartment regardless of the direction of rotation of the impeller. When the valve portion is in its ballasting position, the impeller is idle.
OBJECTS OF THE INVENTION
It is therefore an object of this invention to provide an apparatus for moving a fluid through a passageway into or out of a compartment.
Another object of this invention is to provide a device for pumping water into or out of waterborne vessels.
Yet another object of this invention is to provide a simple and compact valve and pump combination assembly for pumping water directly through the hull of a ship or other vessel without the use of extensive piping systems.
Still another object of the invention is to provide a valve assembly including a fluid impeller for moving water into or out of a compartment with the valve partially or fully open.
BRIEF DESCRIPTION OF THE DRAWINGS
Other objects and many of the attendant advantages of this invention will readily be appreciated as the same becomes better understood by reference to the following detailed description when considered in connection with the accompanying drawings in which like reference numerals designate like parts throughout the figures thereof and wherein:
FIG. 1 is a view, partly in section, of a first embodiment of the valve and pump assembly, in a fully open, deballasting position.
FIG. 2 is a cross-sectional view of FIG. 1 taken along section line 2--2 in FIG. 1.
FIGS. 3-5 depict a second embodiment of this invention, and illustrate the three primary operating positions of the valve and pump assembly; closed, partially open (ballasting) and fully open (deballasting), respectively.
FIG. 6 illustrates a third embodiment of the present invention.
FIG. 7 shows a fourth embodiment of the present invention in its fully open (deballasting) position.
FIGS. 8 and 9 show the valve and pump assembly of FIG. 7 in its partially open (ballasting), and fully closed, position, respectively.
FIG. 10 is a fifth embodiment of the present invention.
DESCRIPTION OF THE INVENTION
Referring now to the drawings, wherein like characters and numerals designate like or corresponding parts throughout the several views, there is shown in FIGS. 1 and 2 a combination sea valve and pump assembly 100 mounted in a floodable compartment in a ship partially in an opening 12 in the bottom 10 of the vessel. Assembly 100 comprises reversible motor 22 fastened to platform 24 spaced above the vessel bottom by supports 26 in the compartment, the motor being submersible and including a grooved female shaft 21 extending downwardly therefrom through the platform toward opening 12. Secured to the underside of platform 24 at a location beneath motor 22 and concentrically spaced about shaft 21 is an upper seat 30 for mating receipt of valve element 40. Notched or grooved surface 32 of upper seat 30 cooperates with inboard surface 41 of valve element 40 to form a seal for preventing sea water from entering the compartment when the valve element is raised to its secured position (See FIG. 3). Also attached to platform 24, peripherally spaced from and about motor 22, are a plurality of hydraulic valve positioners 28 which include piston rods 29 attached through pinned connections to valve element 40. Hydraulic valve positioners 28 are disposed vertically between platform 24 and the valve element for causing the latter to translate in a vertical direction toward and away from ship bottom 10. Valve element 40 includes a plurality of inboard ears or flanges 42 with inboard valve seat 43 disposed adjacent the periphery thereof and outboard flange 44 having outboard valve seat 45 disposed peripherally thereabout. Aligned with inboard valve seat 43 and outboard valve seat 45 of the valve element are inboard and outboard valve seats 14 and 16, respectively, disposed on the vessel bottom. These latter valve seats are provided for sealing cooperation with the valve seats of the valve element when the valve element is disposed in its lowered, or raised, position, respectively. Each inboard flange 42 is unitary with annular body portion 46 and overlies not only opening 12 but also outboard flange 44 (See FIG. 2). Body portion 46 of the valve element includes a central bore which forms a cylindrical housing for impeller 51, the impeller being disposed on splined male shaft 52 and captured between nut 56 and bearing collar 54, the latter being a spider fastened to the inside of the valve element bore. Lock collar 58 is fastened above bearing collar 54 on male shaft 52 to prevent the impeller and male shaft from falling through the bore of element 40 into the sea. Using splined male shaft 52 and splined female shaft 21 permits the valve element, and thus the impeller assembly 50 to be raised and lowered in a direction substantially normal to the ship bottom, through use of the hydraulic valve positioners 28 and without the necessity of raising and lowering the motor or its platform.
Operation of the valve and pump assembly of FIGS. 1 and 2 is more easily understood by referring to FIGS. 3-5, which schematically illustrate a modification of the FIG. 1 assembly and depict the three key operative positions of both embodiments. The assembly of FIGS. 3-5 differs from that of FIG. 1 by the provision of a modified upper seat 30' and valve element 40', upper seat 30' being attached at its upper end to the platform (24 as shown in FIG. 1 but not shown in FIGS. 3-5) on which the motor is mounted. Upper seat 30' includes valve seat 32' for mating contact with inboard valve seat 41' adjacent flange 42' of valve element 40' (See also FIG. 4).
FIG. 3 illustrates valve element 40' in a secured position relative to the bottom 10' of the ship. In this position, sea water cannot enter the ship through the valve element bore inasmuch as contact between inboard seat 41' of valve element 40' and valve seat 32' of upper seat 30' blocks flow of sea water into the respective compartment.
FIG. 4 shows valve element 40' lowered to an intermediate or ballasting position, wherein sea water enters the ship's floodable compartment by passing not only through the valve element bore, but also through the annular opening 12' between the valve element body portion 46' and the ship's bottom 10'. Inasmuch as the motor is reversible, the impeller can be driven in the opposite direction so that sea water is pumped through the valve embodiment bore and into the ballast compartment.
FIG. 5 illustrates valve element 40' disposed in its lowermost or deballasting position, wherein the only way in which the ambient sea water can enter the ship's ballast compartment is through the valve element bore. However, valve element 40' is disposed in this position only when removal of sea water from the ballast compartment is desired, and removal is effected by operation of the impeller designed so that water is pumped out of the compartment. This is facilitated by choosing the impeller and motor such that the pumping head and capacity is adequate to move the desired amount of sea water out of the compartment against the net static head. This latter quantity is defined by the difference between the static head of the water inside and outside the ship plus the head due to friction of the flow of water through the valve. The net difference in head is least when the ballast tank is fullest, and the ship's draft is greatest. As water is pumped out of a compartment, the ship's weight, including cargo and water in the ballast tanks, will decrease and, as the amount of displaced water is reduced, the ship rises higher in the water. Finally, when the ballast tank is emptied, the amount of static head against which the pump must work is maximized and is directly proportional to the draft of the ship in the region of the tank.
FIG. 6 shows another embodiment of the combination sea valve and pump assembly in which the platform (not shown), reversible motor (not shown) and hydraulic lifters (28" and 29") of the pumping assembly are located outside of and above, or at the highest waterline line in, the compartment. The FIG. 6 assembly may include plate 11, shown attached to bottom 10" inside the compartment through weld 13, the plate functioning as a removable segment of ship bottom 10" to accommodate installation of valve element 40" of the valve assembly. Plate 11 is provided with seats 16' which matingly engage seating elements 45" on the outboard flange 44" of the valve element. As with the assembly of FIG. 1, the valve assembly of FIG. 6 is mounted for reciprocable translatory movement into and out of blocking relationship with opening 12" in bottom 10" of the ship. Dependent from the motor is a splined female shaft (not shown), the shaft being joined with male splined shaft 52" at an appropriate location beneath the motor. Supported from the motor support framework and extending along a major portion of the length of male shaft 52" is concentrically encircling watertight stand pipe and shaft casing 62, the lower end of the casing enclosing bearing collar 66 and packing 64. Attached to male shaft 52" immediately below bearing collar 66 is upper seat 30" which is concentrically disposed about male shaft 52", upper seat 30" optionally including sealing gasket 34 attached to notched or grooved surface 32". Only shaft 52", as well as those elements attached thereto, experience translatory movement resulting from application of direct force from the hydraulic lifters. Both valve element 40" and impeller 51" are mounted, and supported by the lower end of shaft 52", in much the same manner as the valve element 40 of the FIG. 1 embodiment. That is, valve element 40" comprises inboard ears or flanges 42" adjacent upper seat 41" (described above), and outboard flange 44" having an upper seat at 45" disposed peripherially thereabout receivable in lower seat 16" of plate 11. Each inboard flange 42" upper seat 41", and outboard flange 44" are unitarily joined by central annular body portion 46", each upper, and lower, flange being configured to overlie an equal portion of surrounding plate 11, as well as one another. Body portion 46" of the valve element includes a central bore which forms a cylindrical housing for impeller 51" disposed on the lowermost end of shaft 52". Impeller 51" is captured between nut 56" and bearing collar 55" housed in spider 54" disposed about the collar. Lock collar 58" is fastened to male shaft 52" above bearing collar 55" to prevent impeller 51" and the male shaft from falling through the bore of valve element 40".
FIGS. 7-9 disclose another embodiment of the present invention in which the valve element includes a two-part housing, the lower part comprising the impeller assembly.
FIG. 7 illustrates valve and pump assembly 400 in its fully open deballasting position. Like the assembly of FIG. 1, assembly 400 is mounted in a floodable compartment in a ship adjacent opening 12''' preferably circular in shape in bottom 10''' of the vessel. Assembly 400 comprises reversible motor 22''' mounted on platform 24''' spaced above the vessel bottom by supports 26''' in the compartment, the motor being submersible and including rotatable grooved, female shaft 21''' extending downwardly therefrom and through the platform 24''' toward opening 12'''. Secured between the underside of platform 24''' and upper impeller casing 42''', and located concentrically about shaft 21''', are a plurality of hydraulic valve positioners 28''' and their respective pistons 29''', each of the pistons, at its lower end, being pinned to upper impeller casing 42''', the impeller casing defining a circle about its outer periphery. The hydraulic valve positioners 28''' and pistons 26''' coact with upper impeller casing 42''' through spider 54''' thereby imparting translatory, nonrotating movement to impeller casing 42''', the latter moving vertically toward and away from ship bottom 10'''. On the surface of upper impeller casing 42''' adjacent opening 12''' in bottom 10''' is outer valve seat 43''', and on the bottom 10''' adjacent opening 12''' are valve seats 14''' (for mating contact with valve seat 43''') and 16''' (for mating contact with valve seat 45''' on the upper surface of impeller lower casing or backplate 44'''). All valve seats mentioned above extend circumferentially about the male shaft and coaction between either seats 43''' and 14''' or seats 45''' and 16''' takes place only upon assembly 400 being fully extended (as shown in FIG. 7) or fully retracted (as shown in FIG. 9), respectively. Like the valve element of assembly 100 of FIG. 1 which includes a central bore forming a cylindrical housing for impeller 50 impeller upper casing 42''' of assembly 400 for FIG. 5 also includes a central bore through which male shaft 52''' extends, the upper end thereof mating with female shaft 21''', the lower end thereof supporting impeller 51''', and the mid-portion of shaft 52''' being vertically positioned within spider 54''' for rotation therein about the vertical axis of the shaft. For this purpose, spider 54''' includes a bearing collar surrounding shaft 52''', and upper and lower shaft collars 59''' and 58''', respectively, for locking the shaft in position relative to the bearing collar as well as for maintaining the appropriate spacing between lower casing 44''', and upper casing 42'''.
Impeller 51''' is substantially trapezoidal as shown in the FIG. 7 cross-sectional view, and includes circular upper and lower surfaces 53''' and 55''', respectively. Positioned about the axis of rotation of the impeller, and extending substantially axially and radially between the upper and lower surfaces, are vanes 57'''. These vanes posses axial curvatures divergent along the body of the impeller relative to the impeller axis of rotation, extending from upper surface 53''' to lower surface 55'''. The vanes are shaped so that, when they are rotated in a predetermined direction, they impel the water axially outwardly from within the ship and toward the radially outermost portion adjacent valve seat 45''' of the impeller. From upper surface 53''' along the body of the impeller to lower surface 55''', vanes 57''' gradually curve radially outwardly so that a generally outward motion is imparted to the water as it is being expelled from the compartment. The direction of exit of the water from the radially outermost portion of the vanes is determined by the curvature of the outermost portion of the vanes. The impeller shown in FIGS. 7-10 possesses what is commonly known as a "mixed flow" design. This invention contemplates use of numerous impeller designs, the use of any one design depending on the exact pumping action or performance desired.
As in assembly 100 disclosed in FIG. 1, the use of splined male shaft 52''' with splined female shaft 21''' permits valve element 40''' of assembly 400, which includes impeller 51''', to be raised and lowered through the use of hydraulic positioners 28''' without the necessity or raising and lowering the motor or the platform.
FIGS. 8 and 9 depict the valve and pump assembly of FIG. 7 in partially open, ballasting position and in fully closed position, respectively. In FIG. 8, sea water enters the ship's floodable compartment by passing not only through vanes 57''' of the impeller but also through the annular opening 12''' between upper impeller casing 42''' and the ship bottom 10'''. FIG. 9 shows the valve and pump assembly in its fully closed position, blocking access of sea water into the ship's floodable compartment. Engagement of valve seats 45''' and 16''' insure prevention of unwanted flow or leakage into the compartment.
FIG. 10 depicts the valve and pump assembly of FIGS. 7-9 where the motor 22''' is not submersible and therefore cannot be located within the floodable compartment. In this arrangement, motor 22''' is usually mounted on a supporting platform 23''' fixed in some conventional manner to the ship structure external to the floodable compartment having centered therein, beneath motor 22''', an opening 25''' through which female splined shaft 21''' extends toward opening 12''' in bottom 10'''. Male splined shaft 52''' is elongated so that it extends through platform 24''', located within the floodable compartment, and interconnects female shaft 21''' with the valve and pump assembly in a splined connection in the same manner set forth in the description for FIG. 7.
There has therefore been described a combined valve and pump assembly for flooding and evacuating a compartment of a ship. The assembly comprises a valve portion located in an opening in the compartment communicating the latter with the sea, and which is remotely actuated to move between a blocking position and at least two unblocking positions. The assembly also comprises an impeller portion carried within the valve portion and actuable when the latter is in any of its unblocking positions to selectively effect the desired flooding or evacuating of the compartment. The valve and pump assembly provides intake into, or explusion from, floodable ship compartments directly through the bottom of the ship, and eliminates the need for any intake or discharge piping. The assembly offers the advantage of conservation of energy required or efficient operation of such equipment by minimizing the loss of power typically attributed to friction in an extensive piping system. Moreover, the weight of deballasting and ballasting equipment, as well as space and cost requirements, is greatly reduced when the present invention is utilized.
Obviously many modifications and variations of the present invention are possible in the light of the above teachings. It is therefore to be understood that, within the scope of the appended claims, the invention may be practiced otherwise than as specifically described. | A combination valve and pump assembly for use as ballasting apparatus in ships includes a cylindrical valve element disposed within an opening in a ballast chamber. The valve element communicates with ambient sea water and is movable toward and away from the ship's outer surface to block and unblock the opening. The valve and pump assembly also comprises pump apparatus, operable with the valve element, and including an impeller rotatably positioned concentrically within the valve element. The invention contemplates simultaneous reciprocatory translation of the valve element and the pump assembly by hydraulic motor apparatus such that opening and closing of the opening by the valve element is effected by the hydraulic apparatus, while a pump motor causes rotation of the impeller when the valve element is displaced from a position where the opening is blocked. | 5 |
BACKGROUND OF THE INVENTION
In order to determine the condition of a patient, and to minimize the diseased state, the need for a rapid diagnosis and appropriate treatment by health care professionals is apparent. Diagnosis of many conditions can be facilitated through the determination or quantitation of antibodies, antigens, nucleotide fragments, and analytes from a biological specimen, which are indicative of a particular disease state or condition. A rapid, sensitive, specific, and simplistic assay is extremely useful for emergency situations, field testing, physicians offices and in home diagnostics. As diagnostic tests become more simple and easier to perform, they are being performed away from the professional clinical laboratory setting to physicians offices and even to the home, where untrained or poorly trained individuals perform the tests usually following product insert instructions alone. These assays are useful provided they are performed properly and are safe to handle for the user. Assays that require multiple steps, have multiple reagents, and have limited storage conditions are prone to misuse, especially if they are performed by individuals without adequate training or skills.
Many types of ligand receptor assays have been developed and commercialized. These assays are less expensive if capital equipment can be eliminated, such as scintillation counters, fluorometers, and colorimeters in the case of radioimmunoassay, fluorescent immunoassay, and enzyme immunoassay respectively. Non instrumental assays, such as latex agglutination, enzyme immunoassays on strips, tubes, membranes or filters have increased the usefulness and ease of performance of immunodiagnostic testing, but are still cumbersome requiring washing steps, multiple reagent additions and usually refrigerated storage conditions.
In some assays amplification or growth of viruses and bacteria are desirable before testing to increase the sensitivity of detection. In other assays adsorption steps to remove interferring substances or inhibitors of the ligand receptor assay, or long incubation of reagents are necessary to perform an assay. Each step for an assay increases the difficulty of testing for the minimally trained individual and any device that would reduce user error would improve diagnostic testing.
Horrisberger et al (J. Histo Cytochem volume 25: 295-305, 1977) described the use of colloidal gold particles in an immunoassay. Leuvering in U.S. Pat. No. 4,313,734 also describe such an immunoassay. Cerny in U.S. patent application Ser. No. 850,253 describes a solid phase immunodiffusion assay using gold sol particles as an immunolabel which can be visualized by the naked eye on a capture membrane, and requires no washing step. Bernstein et al (86th annual American Society for Microbiology Meeting, 1986) presented and described a rapid immunodiffusion enzyme labeled antibody assay for Group A Streptococci on a membrane in which there is no washing step. Gould and Zuk in U.S. Pat. No. 4,552,839 describe the use of colored or dyed beads in a solid phase immunoassay. Through the introduction of colored immunolabelled binding reagents (i.e. gold sol particles, dyed particles, dye encapsulated liposomes, etc.) and the removal of washing steps it becomes possible to perform receptor ligand assays in a closed system with the sequential additions of all reagents within that system.
A number of antigens of interest in the diagnosis of infectious disease are collected with a sterile swab on a shaft to remove the organisms from the suspected infected area or test site (wounds, lesions, blood, tissues, pus, fluids, etc.). The swab is generally used to transfer organisms to a suitable media for culturing which may take as long as 48 hours for growth of bacteria, and 2 weeks for viruses. If the organisms are viable and do grow, then their identification could be made by biochemical, morphological or immunological methods. This time consuming method is slowly becoming replaced by more rapid immunological testing methods or DNA probe methodologies.
In many immunoassays that utilize a swab for collection of antigens or cells, the swab is placed in a solution to release the antigenic materials or cells after collection. It may be necessary to use enzymes, acids, detergents, etc. to solubilize or breakdown the antigens to expose antigenic determinants. The extracted material can then be used in an immunoassay by removing the fluid from the swab and mixing it with other reagents or adding the other reagents directly to the swab extract. In the case where membranes or filters are used to capture the immunoreactants, it is necessary to bring the fluid containing the immunoreactants in contact with the filter or membrane.
In addition, where extraneous cells or debris may interfere with an assay, it may be necessary to have a prefilter (larger pore size filter or membrane) present between the swab and the capture membrane or capture filter to retain these unwanted components.
In some assays, where antigen expression may be low, amplification can be achieved if the organisms are first cultured and then tested. If the culturing and the testing could be performed in a single device, then testing would be simplified. In some assays where there are inhibitors, cross reactive products, or clotting factors, red blood cells, etc., it may be necessary to add adsorbant materials (i.e. beads, kaolin, antibody coated particles, antigen coated particles, or lectin coated particles), anticoagulants, or buffers etc. before the ligand receptor assay can be performed.
It is therefore an object of the present invention to provide a novel test device that utilizes a swab or swab-like material (a shaft with a porous or fibrous absorbant material at one end) to collect a sample and to be able to react the swab with all the necessary reagents which are included within the device, and then to use the swab to transfer the reactants sequentially to other reactants if necessary, and finally to a reaction zone where the specific labelled reactant can be captured and visualized.
It is a further object of the present invention to provide a test device useful in performing ligand receptor assays to detect antigens, haptens, antibodies, DNA or RNA fragments, wherein the user is not required to dispense any of the reagents.
It is a particular object of the present invention to provide a test device that can be stored at nonrefrigerated temperatures, and can be utilized to perform an assay on a biological specimen or fluid without any additional reagents having to be provided to the test device.
In addition it is a further object of the present invention to provide a test device which can utilize lyophilized reagents that can be reconstituted in situ within the device.
BRIEF DESCRIPTION OF THE INVENTION
The present invention maximizes the safety and ease of performance of ligand receptor assays through the use of an apparatus designed to enable a biological specimen to be obtained by a collection device comprising a shaft and an attached adsorbant or absorbant porous or fibrous material (i.e. rayon, dacron, cotton swab) which is inserted into a cylindrical tube. The cylindrical tube contains a sealed vessel or plurality of sealed vessels in sequential order and which the seal will break away or collapse when pressure of the collection device (swab) is exerted on the seal by physically pushing the collection device into and through each vessel. These sealed vessels may contain media, extraction reagents, diluents, labelled antibodies, labelled antigens, labelled lectins,anticoagulants, adsorbants, inactivators, etc. which mix with the biological specimen collected on the collection device. The reagents in these vessels may be lyophilized, enabling long term storage at non refrigerated temperature. The vessels are fixed in position in the cylindrical tube to enable the seals to be broken when physical pressure is exerted on the shaft of the collection device. The collection device holder has appropriate stop points to allow for the collection device tip to enter the appropriate vessel and mix with its contents. A key feature of the vessels are that the tip and shaft of the collecting device can pass through each of the vessels into a lower portion of the cylindrical tube and an attached lower portion comprising a ligand receptor reaction area. The ligand receptor area is comprised of a capture membrane or a filter that will allow unbound reactants to pass through by diffusion and retain the appropriate labelled members of the binding pair. The capturing membrane or filter may be coated with a member of the binding pair to capture the reactants. If capture particles are used, then the capture filter is utilized to retain the particles and allow unbound free labelled antigen or antibody to diffuse through. A prefilter may be used between the collector tip and the capture or filter to remove any nonspecific binding due to debris. An additional absorbant material can be placed behind the capture membrane to increase the uptake of fluid. In either case a specific volume of reactant can be absorbed by controlling the size of the filters and absorbant materials. The configuration of the lower portion allows the collection device to come into physical contact with the prefilter, capture membrane or capture filter.
DESCRIPTION OF THE DRAWINGS
FIG. 1 is a cross sectional view of the invention showing the collection device holder, the collection device, the tube, the sealed reagent compartments and the lower ligand receptor transfer area.
FIG. 2 is a perspective view of the basic structure of the collection device holder and collection device including the grooves for guiding the movement of the collection device through the apparatus.
FIG. 3 is a perspective view of the basic structure of the tube, its compartmentalized reagents, and the nodule which fits into the groove of the collection device holder.
FIG. 4 is a perspective view of the sealed compartments (i.e. vessels) of the apparatus.
FIG. 5 is a cross sectional side view of the lower portion of the apparatus showing the final position of the collection device tip at the window of the ligand receptor area.
FIG. 6 is an exploded perspective view of the ligand receptor test area.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
In the following description, the apparatus and the method will be described in exemplary terms only, for an antigen determining immunoassay test. This discussion, however, is simply to illustrate the structure and use of the apparatus and the technique and steps of the method. The apparatus clearly can be used for any ligand receptor assay in which washing steps have been eliminated and transfer of reactants to or through a porous membrane or filter is used. The best mode, as described hereinafter, is accordingly, to be considered exemplary and not limiting as to the scope and concept of the invention.
Referring first to FIG. 1 for a general depiction of the apparatus, the inventive apparatus comprises a collection device holder 14 which is comprised of a restrictive portion 1 that hold the shaft of the collection device 2 in place, a cylindrical tube 13 which is comprised of one or more sealed reagent compartments 15 and 20, and a lower ligand receptor reaction area 10.
Referring to FIG. 2, the collection device holder 14 has a nodule 16 which positions onto the cylindrical tube and prevents the apparatus from being accidentally opened. When a sample is to be taken, the collection device holder is removed and separated from the cylindrical tube by twisting and pulling up on the collection device holder. This frees up the collection device holder which is then used to collect the test sample (i.e. throat swab, pus, blood, urethral swab, etc.) by allowing the collection device tip 5 to come in contact with the suspect tissue, fluid, wound, etc.
Referring to FIG. 2 and FIG. 3, after obtaining a test sample, the collection device holder is replaced onto the cylindrical tube 13 and turned until the nodule 4 (FIG. 3) on the cylindrical tube is in alignment with the groove 18. The collection device holder is then manually forced downward until the nodule 4 stops at the horizontal groove 19. When the nodule 4 is in contact with horizontal groove 19, then simultaneously the tip 5 will have broken through the first seal (FIG. 4), mixing with the contents of the first vessel 15, then breaking through seal 7 and emptying its contents into vessel 20. The number of independent compartments is related to the number of required reagent additions and incubation steps. One vessel or a plurality of vessels could be used and the mixing of reagents controlled using the principles of nodules and grooves as previously described. In the preferred embodiment, the collection device holder is turned to the right and then back and forth to mix the contents of vessel 20 through the simultaneous turning of the collection device tip.
Referring to FIG. 2 and FIG. 3, after an appropriate incubation time, the collection device holder 14 is turned to the right and thus aligning nodule 4 (FIG. 3) with groove 3 (FIG. 2) and then manually forced downward until the movement of nodule 4 is stopped by the groove end 21 (FIG. 2). Referring to FIG. 5 and FIG. 6 the lower portion 10 may be physically one piece with the cylindrical tube 13 or an attached separate piece. When the nodule 4 is in contact with the groove end 21, then the collection device tip 5 is in contact with the prefilter membrane 25 through the window 11. The reactants flow through the prefilter membrane through holes 24 of adhesive tape 23 which holds the prefilter membrane 25 against window 11. The shape of the lower portion 10 is configured to enhance contact of the collection device tip with the prefilter or reaction membranes. If preferred, the prefilter could be placed on the inside wall of the window 11. In any case, the reactants flow through holes 21 and 22 of adhesive tape 20 which holds membranes 18 and 19 respectively in place. The holes 21 and 22 restrict the flow of the reactants through a capture membrane 19 and a control membrane 18 and enhances the signal of the reaction by concentrating the labelled ligand or receptor binding pairs into a small area. Absorbant 17 absorbs excess fluid diffusing through the membranes. When an appropriate volume of fluid has diffused through the membranes, usually by saturation of the absorbant, the capture and control membranes are visualized within the holes 21 and 22 respectively by lifting the tab 28 of the adhesive tape 12. Adhesive tape 12 holds the absorbant in place and applies the necessary pressure to ensure diffusion of fiuid through the various layers of the ligand receptor test area. The color intensity of the capture membrane 18 is compared to the color intensity of the control membrane 19. A positive result is determined by visualizing a more intense color in the capture membrane than in the control membrane. A negative result is determined by visualizing no significant color or the same weak color in the capture and control membranes. In competitive inhibition assays the positive and negative results are reversed. In the performance of drug analyte assays, the size of the ring of color in a single larger capture membrane is related to the concentration of drug in the test sample. The design of the ligand receptor area, the coating of reagents on the membranes, and the addition or deletion of capture or control membranes are dependent on the particular type of assay being performed. Capture membranes can be coated with antigen or antibody or other complementary ligands or receptors and can be used to determine the presence of different antigens or antibodies. The number of vessels used in the apparatus are dependent upon the type of assay and can contain diluents, media for growth amplification of microorganisms, lyophilized labelled ligands or receptors, etc. The seal 7 (FIG. 4) may be attached to two vessels simultaneously or may be independent. Therefore the vessels could be attached to each other or independent. The following example is illustrative:
EXAMPLE 1
A RAPID IMMUNODIAGNOSTIC TEST FOR GROUP A STREPTOCOCCI
Group C phage associated lysin enzyme which is effective in fragmenting and solubilizing the Group A streptococcal polysaccharide was diluted in a buffer of, 0.05M Citrate phosphate pH 6.1 containing 0.005M EDTA, 0.005M DTT, 0.1% rabbit IgG, 0.05% sodium azide and mixed with Rabbit anti Streptococcal Group A coated gold sol particles (OD518 1.5) diluted in a buffer of 0.02M Tris pH 8.2 containing 1.0% BSA, 0.2% sodium heparin, 0.5% n acetylglucosamine and 0.02% sodium azide in a ratio of 3 parts lysin reagent to 1 part antibody gold sol reagent. The combined reagent was sterile filtered through a 0.2 micron cellulose acetate filter and 200 microliters were aliquoted into acrylic walled reaction cup vessels, having an aluminum foil sealed bottom. The aliquots were frozen and lyophilized. The reaction cup vessels were sealed with aluminum foil and contact cement under nitrogen. Another reaction vessel was cemented to the aluminum foil lid of the first vessel. Two hundred microliters of distilled water was added to the second vessel and then cemented and sealed with aluminum foil. The vessels were placed and positioned into the cylindrical tube. The ligand receptor area was prepared by coating nitrocellulose membranes with rabbit anti group A streptococcal antibody for the capture membranes, and normal rabbit immunoglobulin for the control membranes. The membranes were dried and fixed to a diacetate laminate which had 1.5 mm diameter holes for each membrane. A 1.2 micron cellulose acetate prefilter was used to cover the window of the lower portion of the device. A dacron tipped swab was seeded with varying concentrations of group A streptococci. The swab was placed into the cylindrical tube and forced downward to break the first two seals on the reaction vessels. The swab incubated for 4 minutes at room temperature allowing the lysin enzyme to solubilize the Group A streptococcal polysaccharide and the reaction of the gold labelled anti Group A antibody to form complexes with the released polysaccharide. After four minutes the swab was forced downward through the third seal into the lower portion, coming in contact with the ligand receptor area. The fluid diffused through the prefilter into capture and control membranes. After 30 seconds the tab of the ligand receptor area was pulled away from the lower portion and visuallized. A distinct color reaction with 2×10 3 organisms of Group A streptococci could be distinguished in the capture membrane compared to the colorless control membrane.
The foregoing disclosure and the showing made in the drawings are merely illustrative of the principles of this invention and are not to be interpreted in a limiting sense. It is understood that through the example and embodiments described herein, that various modifications in light thereof will be suggested to persons skilled in the art to be included in the spirit and review of this application and the scope of the approved claims. | A device for a self contained solid phase immunodiffusion assay. The device is comprised of a sample collector, a tube with compartmentalized reagents and a ligand receptor capture membrane filter area. The seals can be broken through pressure on the sample collector. The sample collector is pushed through the seals, mixed with reagent, and then pushed into a ligand receptor reaction area wherein the tip of the sample collector contacts diffusable membranes or filters and transfers the reactants to a capture membrane wherein a ligand receptor reaction can be visualized by the naked eye. | 1 |
FIELD OF THE INVENTION
The invention relates to a press for continuous pressing of assemblies of multiple sheets or discs of insulating glass to form insulating glass panels, with shaped frames inserted as spacers between the sheets, the frames being provided on both sides with sealing material, the and press being equipped with a plurality of press members comprising a pair of compression heads with an adjustable spacing between them for transverse compression of the leading and trailing edges of the panels and with a pair of cylinders with an adjustable spacing between them for longitudinal compression of the sides or side edges of the assemblies or panels, with means to carry the assemblies from an inlet loading zone through the compression members to an outlet discharge zone
DESCRIPTION OF THE PRIOR ART
The most relevant prior art known to applicant is represented by U.S. Pat. No. 4,030,961, issued June 21, 1977, to Straeten, et al, U.S. Pat. No. 1,960,580, issued May 29, 1934 to Frazer, and U.S. Pat. No. 1,897,862, issued Feb. 14, 1933 to Randall.
In the prior art, in order to achieve an intimate connection between glass disks and a spacer frame in multiple discs insulating glass, and a distribution of sealing material between them over the widest possible area, the discs are placed together and are then pressed by means of two rolls or cylinders rotating in opposite directions. In order to obtain a wedge angle as flat as possible which permits a favorable pressure distribution in the glass and prevents the breaking thereof, it is necessary to employ press rolls with a relatively large diameter. This, however, unfavorably affects the weight and the volume of the machine.
In the pressing of a multiple-disk insulating glass panel, a very high pressure is necessary for a short time during the passing of a transverse edge, in order to obtain the necessary area pressure over the entire width of the disk. In this process there exists the risk of a glass breakage. Besides, it is unavoidable that the relatively great forces acting upon the bearing ends of the press rolls cause a bending of the rolls, so that smaller pressure ratios prevail in the center than on the outside or edges. The result is that the front and rear transverse edges of the disk package do not undergo a uniform pressing. The pressure required for the longitudinal or side edges is much too high for the transverse edges, so that a corresponding reduction of pressure is necessary. This requires a corresponding control expenditure. (German Gebrauchsmuster No. 73/6310 to Karl Lenhardt, dated Oct. 31, 1973).
SUMMARY OF THE INVENTION
The primary object of the invention is to provide a continuous press for multiple-disc panels such as of insulating glass which permits a satisfactory transverse edge as well as longitudinal edge-compression.
Another object of the invention is to provide a beam press in combination with a pair of cylinders and disposed transversely to the direction of conveyance, the beam press arranged to press the leading and trailing edges of a panel, and the cylinders arranged to press the side edges of the panel.
A further object is to provide a press for pressing panels of insulating glass, wherein a beam press for pressing the leading and trailing edges of panels is provided in association with cylinder presses for pressing the side edges of the panels, the beam press being movable in the direction of movement of the panel as well as perpendicularly thereto.
Yet another object is to provide a press for pressing flat panels, wherein the press includes means for sensing the width of a panel to be pressed and for adjusting the pressure of the press to avoid excessive pressure per unit area on the panel.
Another object of the invention is to provide a uniform compression of the transverse edges of the assembled disk packages by separate processing of the transverse and longitudinal edges. This permits a decrease in the diameter of the press cylinders, an increase in the passing speed of the disk packages up to 100% and a strong adaptation to the general transportation speed within the production line, whereby the production rhythm is positively affected. Since the pair of cylinders serves only for compressing the longitudinal edges, it can be entirely adjusted to this function. This leads, in connection with the lower pressing pressure, to substantially lighter cylinders with smaller diameters. This in turn has an advantageous effect upon the weight and the volume of the machine.
BRIEF DESCRIPTION OF THE DRAWINGS
FIGS. 1 to 6 depict in diagrammatic representations a first embodiment of a continuous press according to the invention. The several figures represent various operating phases of a continuous cycle.
FIGS. 7a to 7f depict in diagrammatic representations an improvement of the continuous press according to FIG. 1, with a beam press displaceable relative to a pair of compressing cylinders.
FIG. 8 depicts in diagrammatic representation, partly in section, a front view of a beam press according to the invention.
FIG. 9 depicts in diagrammatic representation a pair of cylinders during a pressing operation.
FIG. 10 is a simplified diagrammatic representation of the method steps of the invention.
FIG. 11 is an exemplary diagrammatic representation of the pneumatic controls of the press.
FIG. 12 is an exemplary diagrammatic representation of the circuitry of the invention.
Repetitions of descriptions of reference numerals for parts common to the various figures were omitted for purposes of brevity.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
In the drawings, wherein the same reference numerals denote the same or equivalent parts throughout the several views, an upper compression cylinder 1 and a lower compression cylinder 2 are mounted in a housing, not shown, and are for rotation, spaced from each other in parallel relationship, with their shaft-ends 1c and 2c respectively, in vertical alignment.
The cylinders are provided with an elastic coat 1a and 2a respectively. Means 22 are provided to drive the cylinders synchronously in opposite directions. The lower cylinder, taking into consideration its elastic coat, defines with its upper surface tangent a conveyor plane 20 for a disk or panel assembly or package 14 to be compressed for purposes of gluing its periphery together. While the invention is demonstrated hereinafter for purposes of simplicity of explanation with the conveyance path of the disk assembly depicted and hereinafter described as horizontal, it is also applicable to an apparatus and method employing a conveyance path at an angle from horizontal and preferably also to one having a vertical path. As shown on FIG. 9, the lower cylinder is located stationary relative to the ground and the path of conveyance of the disk package. It is mounted relative to a rear conveyor track 4, which is equipped with rear conveyor rollers 5 and 5', arranged on either side of the lower cylinder 1, spaced therefrom and lying with their upper horizontal tangent in the conveyance path 20. Means 5a are provided to drive the rollers 5 and 5' separately. A roller front switch 6 and a roller rear switch 7 are located in the direction of the path of conveyance between the lower cylinder and the rollers 5 and 5', respectively. Upper cylinder adjusting means 24 are connected to the shaft ends thereof for its vertical adjustment relative to the lower cylinder. Conventional pneumatic or equivalent means are suitable therefor.
A crossbeam 3 mounted to the upper cylinder projects into the path of motion of a portion of a beam press 26. The beam press has an upper head 9 and a lower head 9. The heads are arranged in vertical alignment in front of the pair of the cylinders 1 and 2 in the direction of the passage or conveyance of a glass package or assembly 14, shown by arrow "A". The beampress extends transversely to the direction of the passage and over the operational width of the machine. The operating surfaces of the two press heads are provided with elastic coats, 8a and 9a, respectively, such as a rubber coat. The lower press head is provided with means to reciprocate it into a position of rest below the level of the plane of conveyance as shown on FIG. 1 and to raise it into a position of alignment, shown on FIG. 2, for the purpose of the pressing operation, so that its rubber coat protrudes above the level of the conveying plane 20.
The upper press head is vertically adjustable by means 30 such as pneumatic means. A cam 10 is fixed on the upper press head, or equivalent means such as electric, hydraulic or pneumatic movers are provided, to establish via crossbeam 3 an operative connection to the upper press roll 2.
A front conveyor track 11 is mounted in the direction of conveyance in front of the lower press head. This track is provided with driving track rollers 12 with means 12a to drive them separately. In order to convey the multiple-panel insulating glass package assembly through the press, coupling means 32 are provided to couple the conveyor tracks 4 and 11 to make them operable as a driving mechanism.
A front track switch 13 is provided between the lower press head and the front conveyor track at the level of the conveyor plane.
The operating sequence of a work cycle of the continuous press is now explained, first with reference to FIGS. 1 to 8. As an assembled disk package is transported over the conveyor track 11, it triggers the front track switch 13. Thereby the drive of the conveyor track 11 is shut off (as more fully explained hereinafter) and the disk package 14 comes to a rest in the area of the beam heads in the position shown on FIG. 1.
The pneumatic mechanism 30 of the beam heads 8 and 9 is acted upon through switch 13 with a predetermined delay, and the lower press head is lifted to the position shown in FIG. 2. The upper press head is lowered, and in this operation it carries the upper cylinder downward via engagement between the cam 10 and the cross beam 3. This press cylinder reaches in this stage a preliminary terminal position in which the spacing "S" between the surfaces of the two cylinders is by a few millimeters larger than the thickness of the disk package which in the meantime has been pressed in the frontal edge area by the beam press as shown on FIG. 2.
In order to achieve a uniformly good compression, even at large widths of the disk package, and to avoid at small disk dimensions development of excessive surface pressures which possibly could result in the breaking of the disk package, particularly when it includes glass panels, a plurality of scanners 15 spaced under the operating conveyance level over the operating width of the apparatus are provided in the entrance area of the operating surface area of the lower press head as shown on FIG. 8.
The scanners include any conventional means of detecting or identifying dimensions, spacings or distances, such as electric switches, cam or magnetically operated switches, photo-cells and equivalents.
Each of the scanners controls one pressure valve which in its turn controls the beam press. The valves are combined with pressure reducers 34 (FIG. 11) so adjusted that starting from a disk with one edge located at 16, shown on FIG. 8, the outgoing pressures of the valves are of different intensities, increasing in succession as the width of the panel or discs increases from edge 16. Commercially available pressure reducers of conventional construction suitable for the purpose are made for instance by the Norgren GmbH, Dusseldorf, West Germany. Corresponding to the prevailing width of a disk package, one or more of the scanners 15 are switched on and thereby their associated valves are actuated. Thus, these valves permit automatically, corresponding to their respective pressure gradations, to reach the beam press via pneumatic or hydraulic cylinders with an approximate compression that is specific for the given width of the disk package. Valves of conventional designs suitable for the purpose are commercially available from WABCO Westinghouse Corporation.
The automatic adjustment of the compressing pressure to the width of the disk package assures a steady, uniform desired compression. Thus, immediately before each compression of the transverse leading or trailing edge, the edge length is determined by the scanners 15, and the corresponding pressure is set. This is also advantageous when a disk package has a geometric shape deviating from a rectangle, such as when the lengths of the front and of the rear transverse edges are different.
The sequence of the scanners spaced from each other thus performs simultaneously a scanning function as well as a valve control function.
The scanning principle is particularly important when irregular or assymetric package disk shapes are involved which extend, for example, toward one end with a pointed or trapezoidal shape. Because of the latterally arranged scanners, the beam press in such instances is cut out of operation when a specific minimum width is reached. With a very short transverse edge or if such edge is non-existent, the necessary compression is taken care of during the passage of the package between the pair of cylinders.
If the width of the package is sufficient to be pessed, after the compression of the leading transverse edge of the disk package according to FIG. 2, the beam press releases it by the return of the lower press head to the position of rest and by the lifting of the upper press head by a few millimeters, as shown on FIG. 3.
The upper cylinder remains in the position once assumed. With the opening of the beam press, the rolls of the conveyor tracks 4 and 11 are driven synchronously, so that the disk package is fed to the pair of cylinders. In the course of this advance, the disk package actuates the first rear switch 6 which results in a further lowering of the upper press cylinder. The sequences are chosen in such a way that the upper cylinder comes to rest upon the edge area previously compressed by the beam press. Immediately following this operation, the compressing pressure pre-set at the pressure reducer 34 is built up, and the longitudinal edges of the disk package are compressed while the disc package is passing between the cylinders.
As shown on FIG. 9 in an exaggerated manner, the press cylinders extending over the whole operating width of the disk package are bent and compress the disk package 14 in such a manner that they bulge outwardly in their centers. Since in the present embodiment, the press rolls have only the function of compressing the longitudinal edges of the disk package, the outward bulging does not have a negative effect. The tilting of the cylinders produced thereby relative to the disk package is so slight that it is compensated by the elastic coats of the rolls.
Further, because the function of the cylinders in this instance is limited only to the pressing of the longitudinal edges of the disk packages, it is within the scope of this invention to replace the cylinders by pairs of rollers adapted to the edge pressing width, with one of the pairs adjustable axially to the prevailing disk package width. This requires an additional manual or automatic adjusting device. This arrangement, however, is not applicable to disk packages which, due to a deviation from the rectangular shape, do not have the longitudinal edges in parallel. With the use of cylinders which extend over the entire operating width of the apparatus, these problems do not occur.
The compression of the longitudinal edges of the disk package in their passage takes place without interruption until the trailing transverse edge of the disk package has released switch 13 as shown on FIG. 4. The switching operation connected therewith stops the drive of the conveyor tracks and of the pair of cylinders, which remain in a compressing position. Thus, the disk package comes to rest in the position shown on FIG. 4, with its trailing transverse edge positioned underneath the beam press. The beam press carries out the compression of the trailing transverse edge of the disk package in the manner described above in connection with compression of the leading edge. With the subsequent opening of the beam heads, the drive of the conveyor track and of the cylinders is switched on again automatically and the disk package is moved on and through between the cylinders. In the meantime, both press heads automatically return to the initial position, as shown on FIG. 5. The release of the first rear roller switch 6 prepares the lifting of the upper cylinder and its return to the initial position. It starts when the rear transverse edge of the disk package passes the cylinders. With the release of the switch 6, the drive of the conveyor track 11 is also switched on again. A next following disk package 14' is therefore fed to the press. With the actuation of the track switch 13 the drive of the conveyor track is switched off again in such a way that the following disk package 14' comes to rest in the position shown on FIG. 5 in the area of the beam head. Actuation of the beam heads as already described, however, is released only when the second rear roller switch is no longer actuated. According to FIG. 6, this occurs only after the disk package has safely passed the area of the cylinders and has released switch 7. Therewith a new operating cycle starts immediately, initiated by the following disk package 14' which already has previously been conveyed into the area of the beam heads, since the track switch 13 has already been actuated.
With the aid of FIGS. 1 to 6, the course of a work cycle of the continuous press explained above is described in the following in greater detail with particular reference to FIGS. 11 and 12.
With the feeding of a disc package 14 via transportation track 11, switch 13 is actuated, the latter switches via its contacts sets 13/1 and 13/2 the drive of the transportation belt 11, by switching clutch 25 to break 26 (FIG. 12), off in such a manner that disc package 14 comes to a standstill in the position shown in FIG. 1, in the area of beam press 8, 9. With a correspinding time delay, the pnumatic mechanism of beam press 8, 9 is actuated via switch 13 in that via a contact set 13/3, a magnetically actuated pilot 44 is energized and thus actuated. According to FIG. 11, pressure is thus exerted upon the right chamber of the pressure cylinder 42 and is conveyed therefrom to the bottom press beam 8, so that the latter is moved up to its upper terminal position. At the same time, contact set 13/4 is closed and contact set 13/5 is opened, thereby via a magnetically actuated servo valve 481 a two way pilot valve 48 is shifted to the position wherein pressure cylinder 41 is impinged upon by pressure so as to actuate the upper press beam 9 in a downward direction. Thereby, the upper beam 9 is lowered. Throttle check valves 47 regulate the lifting speed in both directions. By way of carrier 10 and arm 3, the upper press beam 9 carries along upper press roll 2 in a downward direction. During the pressing of the front disc package edge, the upper press roll 2 reaches a preliminary terminal position in which the distance between the surfaces of the two press rolls 1 and 2 is larger by some millimeters than the thickness of disc package 14 (FIG. 2) which is pressed in the front or leading edge area by beam press 8, 9.
In order to assure on the one hand, even at great disc widths, a pressing as uniformly strong as possible, but on the other hand to obtain, even at small disc dimensions, no excessive surface pressures which may cause a break in the disc package, a progressive adaptation of the press pressure to the width of the disc package to be pressed takes place. For this purpose, a number of scanners or switches 15 are arranged in the entrance area of the working surface of the lower press beam 8, as shown in FIG. 8. They are distributed at suitable distances over the working width, starting from a disc abutting edge 16.
In FIG. 11, these switches 15 are marked 15/1 to 15/IV in their different spacing from the disc abutting edge. Each of these switches 15 has two contact sets 1 and 2 (FIG. 12). Contact sets 15/I-1 to 15/IV-1 are parallel to each other and connected in series with a relay switch 50 which switches via its contact set 50/1 the current supply for four magnetic valves 41/I to 45/IV. In the current supply line leading to these magnetic valves, the respective second contact sets 15/I-2 to 15/IV-2 of switches 15/I to 15/IV are provided. As shown in FIG. 11, magnetic valves 45/I to 45/IV are connected in the initial position shown so that the pressure can be transmitted from one to the other. While magnetic valve 45/IV is directly connected to the common pressure line 30, magnetic valves 45/I to 45/III are connected via precision pressure regulators 411/I, 411/II, or 411/III. These precision pressure regulators are preset to prespecified values which are proportional to the pressure gradations and which are set by switches 15/I to 15/IV. The outlet of magnetic valve 45/IV is connected via a control line 31 with a pressure regulator 46 which is provided in the pressure supply line leading to the aforementioned pilot valve 48.
The tuning of the press pressure of beam press 8,9 to the edge width of disc package 14 to be pressed takes place in connection with the pneumatic mechanism described above in the following manner: Main switch 24 must be actuated and thus relay switch 51 must be energized so that its switch contacts 51/1 and 51/2 are closed. According to what has been described above, contact sets 13/3 and 13/4 are closed, while 13/5 is open, i.e., the lower press beam 8 is lifted and two way pilot valve 48 is opened so as to lower the upper press beam 9. The pressure reducer 34 produces a pneumatic counterweight to press beam 9. One or more switches 15/I to 15/IV, depending on the width of the disc package 14 (FIG. 8) which is conveyed into the work area of beam press 8,9, are covered and thus actuated. It will be assumed that the disc package 14 has a width between 500 and 1200, so that switches 15/I and 15/II are in the state of operation. Thus, contact sets 15/I-1 and 15/I-2 as well as contact sets 15/II-1 and 15/II-2 are closed. Relay switch 50 is connected to a separate circuit via parallel contacts 15/I-1 and 15/II-1, and is therefore energized, and the switch contact 50/1 of this relay switch 50 connects the switch contacts 15/I-2 to 15/IV-2 to voltage, of which contact sets 15/I-2 and 15/II-2, as described above, are closed. The magnetic valves 45/I and 45/2 thus connected to voltage switch the circuit from the through position to its respective precision pressure regulator 411/I or 411/2, respectively. Magnetic valve 45/I becomes ineffective, via the response of magnetic valve 45/II, while precision pressure regulator 411/II is connected to magentic valves 45/III and 45/IV, which are still in the through passage state, via magnetic valve 45/II. Thus, the pressure set in precision pressure regulator 45/II, which is proportional to the disc package width between 500 and 1200, is connected via control line 31 to pressure regulator 46. Dependent on this control pressure, which varies from on pressure stage to the other, pressure regulator 46 opens more or less, so that in connection with a pressure reducer 410 as pneumatic counterweight, in each case only the pressure that is specific for the disc package width reaches the left chamber of pressure cylinder 41. This automatic gradation of the press pressure to the disc package width assures a constant pressing. This is also advantageous, for example, when a disc package presents a geometrical shape deviating from a rectangle, i.e., when the lengths of the front and rear transverse edges are different. In disc types which, for example, extend toward one end with a pointed or trapezoidal shape, the scanning principle described above is of special importance. When the rear edge length of such a disc package is, for example, below 250, none of the switches 15/I to 15/IV is actuated so that automatically a pressing is prevented. In the event the transverse edge is very short or non-existent, the necessary pressing is carried out, in the course of the following passage, by the pair of rolls 1 and 2.
After the pressing of the front transverse edge of disc package 14 according to FIG. 2, contact sets 13/1 and 13/5 are closed, and 13/2, 13/3 and 13/4 are open. The switching operation of contacts 13/1 and 13/2 acts in a delayed manner so that meanwhile pilot valve 44 can return to the initial position shown in FIG. 11, wherein the pressure free cylinder 42, damped by the net weight of the lower press beam by way of a throttle valve 417, returns to the lowered position. Simultaneously, by the shifting of two way pilot valve 48, the result is accomplished via the then energized servo valve 482 that the upper press beam 9 is lefted from the disc package 14 by some millimeters, as shown in FIG. 3. The upper press roll 2 remains in the position one assumed. With the opening of the press beam 8,9 the delayed effect of contact sets 13/1 and 13/2 takes place, so that brake 26 is released and clutch 25 is engaged again. Thereby, the rolls of conveyer belt 11 and 4 are synchronously driven, whereby disc package 14 is fed to the pair of rolls 1, 2. In the course of this advance, disc package 14 actuates switch 6 which in turn actuates a pilot valve 54. In this position, pressure cylinder 43, which acts upon the upper press roll 2, is connected via a pressure reducer 49 with a pressure line 30. By this pressure reducer a prespecified weight portion of the upper press roll 2 is compensated by a pneumatic counterweight, so that it rests with a defined part of its net weight on disc package 14. The sequences are chosen in such a way that press roll 2 comes to rest upon the edge area previously pressed by beam press 8,9 and presses the longitudinal edges of disc package 14, in the passage of the disc package between the rolls 1 and 2.
When a pressing of one or a sequence of disc packages cannot take place, main switch 24 must be opened. The relay switch 51 thus becomes currentless and interrupts via its switch contacts 51/1 and 51/2 the circuits leading to the beam press control and press roll control.
When standard measurement assemblies are to be processed, it is within the scope of the invention to provide a second pair of compression heads, or a plurality of such pairs, spaced from each other distances such as required for spaced transverse sealings of the assemblies, such as the distance between their leading and trailing edges, and to operate the heads for compression of the leading and trailing edges in situ simultaneously.
As shown on FIGS. 7a to 7f, an additional improvement the invention permits a continuous operation free of interruptions. However, it requires a specific minimum length of the disk package 14 which is to be pressed.
The mechanical structure corresponds essentially to that described in connection with FIG. 1. As a basic difference, however, the beam press with the associated conveyor track 11 is displaceable in longitudinal direction relative to the pair of cylinders with the associated conveyor track 4. The length of the path of displacement "S" of the beam press results from the speed of advance, taken as a base, of the disk package which is to be pressed, and the duration of the edge pressing. Therefore a means 3b to move the beam press is provided.
With the entrance of a disk package into the area of the beam press, the front track switch 13 is actuated. By way of this switch 13 the beam press is set in motion in the direction toward the cylinders. It has reached the speed of advance of the disk package when the front transverse edge thereof is positioned approximately in the middle underneath the beam press 8,9 as shown on FIG. 7a. At this moment, the beam press closes. In the course of the further advance, the front transverse edge of the disk package is compressed. The operation is finished when the beam press which moves along has covered the distance of the displacement "S" as shown on FIG. 7b. For instance by striking, the beam press opens and returns with an increased speed to the initial position as shown on FIG. 7c. The conveyor track 11 of the previous embodiment of the beam press can be driven in this process in such a way that it even supports the advance of the disk package. The disc package thus moves with a continuous advance to between the pair of cylinders. In the initial position the beam press awaits the entrance of the trailing transverse edge of the disk package, which in turn is signaled by the switch 13 as shown on FIG. 7d. As described with relation to FIG. 7b, the beam press is set in motion with the speed of the disk package and closes simultaneously. During the longitudinal displacement over the distance "S" the trailing transverse edge of the disk package is also compressed during the longitudinal displacement. When the terminal position is reached, the beam press opens again as shown on FIG. 7e and returns subsequently to the initial position shown on FIG. 7f, wherefrom in case of need a new cycle of operations starts without interruption. The method of the invention is shown in a simplified block diagram on FIG. 10. The longitudinal speed of the cylinders 41, 42 and 43 may be controlled for instance, by chokes installed directly in the cylinders. Means for a fine control of the compression is further provided by the pressure reducer 34 which exerts sufficient counter pressure to provide a soft, gentle contact with the panel.
The embodiments described above of the continuous press are suitable for horizontal as well as vertical operation. The latter presents the advantage that it can be combined without difficulties with other vertically operating machines of a manufacturing plant. Besides, the vertical version requires smaller floor space and permits an easier processing of the disk packages with large surfaces since glass disks placed upon the spacers have a tendency to bend at horizontal processing.
Instead of the conveyor rolls other conveyor means such as an endless belt may be employed.
While the lower cylinder has been described as mounted stationary, it is within the scope of the invention to reverse or alter the arrangement in such a manner that at least one of the cylinders is moved relative to the other to an assembly package compressing distance and the means to actuate the vertical reciprocation of the upper cylinder in such an instance is means to actuate the vertical reciprocation of either or both of the cylinders.
It is within the scope of this invention to reverse the sealing sequence which starts with the transverse compression by the heads followed by the longitudinal compression by the cylinders. | A press for pressing assemblies or panels of multiple flat sheets or discs of insulating glass, has at least two pairs of upper and lower press members between which the panels are conveyed, and switches are disposed in the path of the panels to cause timed operation of the press members to sequentially press the leading, side and trailing edges of the panels as they pass between the upper and lower press members. Sensors are arranged in the path of the panels to detect the width of the panels and adjust the pressure exerted by the press members to prevent damage to narrow panels. | 4 |
BACKGROUND OF THE INVENTION
This invention relates to a method of preparing feed grain compositions for livestock. More specifically, it relates to a process involving the fermentation of a mixture of animal wastes and grain.
Animal production based on confinement of animals in large groups means that animal wastes also are confined. This waste can be considered a raw material whose on-site concentration allows continuous collection and processing. For example, animal wastes contain sufficient nitrogen in the form of protein (ca. 20% of total N) and in forms readily convertible by microorganisms to protein (urea and ammonia nitrogen constitute ca. 30% of total N) to be potentially useful as a nutrient source for feeds.
Animal wastes have been collected and refed without further treatment to the same or different species, generally as a nitrogen source. These studies have been discussed by Anthony (J. Anim. Sci. 32: 4, 799-802, 1971) and extensively reviewed in detail by Smith ("Recycling Animal Wastes as a Protein Source," Symposium on Alternate Sources of Protein for Animal Production, Amer. Soc. Anim. Sci. and Committee on Animal Nutrition, Nat. Res., 1972; and "Nutritive Evaluations of Animal Manures," pages 55-74, In: G. E. Inglett, ed., Symposium: Processing Agricultural and Municipal Wastes, Avi Publishing Company, Westport, Connecticut).
In his report, Anthony stated that "it is detrimental to feed quality if manure is even partially decomposed by ubiquitous aerobic microorganisms."
In contrast to direct refeeding, feedlot manure has been ensiled (an anaerobic fermentation) with roughage (57 manure:43 hay, w/w; ca. 20% manure, dry basis) and termed Wastelage (Anthony, Proc., Conf. on Animal Waste Mangement, Cornell University, Ithaca, New York, pages 105-113, 1969; and Livestock Waste Management and Pollution Abatement, Proc. Int. Symposium on Livestock Wastes, Amer. Soc. Agri. Engineers, St. Joseph, Michigan, pages 293-296). The ensiled mixture fed at 40% of a corn ration afforded satisfactory gains, although feed:gain ratios are somewhat higher than with control rations. An anaerobic lactic fermentation of whole manure neutralized with anhydrous ammonia also has been reported (Moore and Anthony, J. Anim. Sci. 30: 2, 324, 1970), and acid treatment of the cellulosic fraction of manure to provide a substrate for yeast production has been proposed (Singh and Anthony, J. Anim. Sci. 27: 4, 1136, 1968).
We have found a method of preparing animal feed compositions comprising the steps
P1 a. mixing from 2 to 15 parts, dry weight basis (dwb) of animal feedlot waste (FDW) with 100 parts dwb of fragmented grain (FG) and an amount of water such that the resulting mixture contains from 35% to 45% moisture; and
b. aerobically fermenting the mixture resulting from step (a) while submitting the mixture to a tumbling action for a time sufficient to obtain a pH in the mixture of from 4 to 5.
A major advantage of the above method is the simplicity of operation. Each step can be accomplished on the feedlot site in easily obtainable and relatively inexpensive equipment. Daily production of waste can be used up quickly so that the problems of waste accumulation are eliminated. The product, when dried to ordinary corn storage conditions, can be stored in the same manner as corn.
Another major advantage is that the fermentation is aerobic and does not require the controls necessary to anaerobic fermentations. No pH control is necessary.
Microorganism growth is selective to lactobacilli while coliform and other organisms found in feedlot waste are eliminated. Within a short time after fermentation begins, fecal odor disappears and is replaced by a more pleasant silage-like odor. Possible health and pollution hazards inherent in the waste are reduced in the early stages of fermentation. Most of the nitrogen contained in the waste is conserved while the waste is converted to a feed having more more desirable amino acid compositions.
DETAILED DESCRIPTION OF THE INVENTION
The process is simple and is adaptable to both small and large animal units. It depends upon the fact that all livestock contain enteric bacteria including lactobacilli. Fresh wastes from the livestock inherently contain lactobacilli, usually about 1% of the total bacteria. All livestocks wastes are therefore useful as starting materials in the method of the invention. However, the discussion will be limited to feedlot wastes (FLW) which are easily collected. If economical methods of collecting other livestock wastes are discovered, they will also be suitable for use in the invention.
It is preferred that FLW used as starting materials be fresh. Weathered FLW do not yield optimum fermentations unless inocculated with lactobacilli.
The term FLW is defined herein to include the wastes from any feedlot animal such as hogs and cattle and FLW fractions such as feedlot waste liquids (FLWL) unless otherwise specified.
Hog FLW is relatively free from fibrous solids and is used directly without separation. Cattle FLW, which contains fibrous solids equaling up to 40% of total solids, also is utilized directly without separation, but it is preferable to remove the fibrous solids before mixing with the fragmented grain. Cattle FLW diluted with water to a solids content of from 3% to 20% is easily separated into a fibrous solid fraction and a liquid fraction (FLWL) containing from 2% to 15% solids.
Liquids obtained by hand squeezing the diluted waste through layers of cheesecloth or by gravity separation on a 30 -mesh screen contain from 20% to 40% of total raw waste solids. Approximately 90% of readily soluble and finely dispersed solids are partitioned into the liquid upon initial separation.
Any livestock feed grain is suitable for use in accordance with the invention including corn, wheat, and milo. Since microorganisms grow on the porous starch and not the hull of the feed grain, the grain kernels must be fractured or fragmented to expose the inner starchy parts to the fermentation media. Suitable means of accomplishing this include cracking, flaking, grinding, roller milling, and hammer milling. It is preferred that the particles resulting from the fragmentation be relatively coarse.
Grain and FLW are mixed together in quantities such that there are 2 to 15 parts dry weight basis (dwb) FLW solids per 100 parts dwb fragmented grain (FG,) and that the final moisture content of the FG-FLW mixture is from 35% to 45%. Since it is desirable to utilize as much FLW as possible, a mixture containing less than 2 parts FLW per 100 parts FG would be impractical. Mixtures with more than 15 parts FLW per 100 parts FG result in poor fermentations and retention of the fecal odor.
Moisture levels significantly less than 35% are insufficient to promote fermentation while those over 45% result in agglomeration of the grain particles and reduction of the tumbling action. There is no free liquid present in the mixtures at these moisture levels. The mixtures appear dry. The preferred moisture levels are from 38% to 42%.
Diluting raw cattle FLW to from 3% to 20% solids, separating the fibrous fraction by the methods described above, and mixing the FLWL with corn in suitable ratios of FLW solids:FG dwb resulted in a moisture level of about 40%. With raw wastes it is usually necessary to add water to achieve the proper moisture content.
Incubation is carried out in a container having a configuration and motion that provides a tumbling action to the FG-FLW particles. This was accomplished in containers of various shapes which were nearly horizontal and which were rotated at a speed that carried the particles up the side of the container until they fell back, tumbling over the particles below.
Flasks mounted perpendicularly to a nearly vertical rotating board, cylindrical containers rotating about nearly horizontal axes, and the like are suitable for incubation. The containers must be open to the air so that sufficient oxygen will be provided to support the aerobic fermentation which is enhanced by the tumbling action. Cement mixers are particularly suitable. No temperature control is necessary when the fermentation is conducted at the preferred ambient temperatures of from 18° to 38° C., thereby making the method ideal for on-site use.
Control of pH is also unnecessary.
The FG-FLW mixtures have initial pH's of from about 5.5 to 7.5. During fermentation pH of the mixture decreases to a minimum of from 4 to 5 at which time (usually 24 to 36 hours) growth of lactobacilli is essentially complete. Incubation is terminated when the pH of the mixture reaches 4 to 5, preferably 4 to 4.5. The product is fed directly to the feedlot animals, or it is dried, preferably at ambient temperatures, to a 12% or less moisture content for storage.
The following examples are intended to further illustrate the invention and are not to be construed as limiting the scope of the invention which is defined by the claims, infra.
All parts and percentages disclosed herein are by weight unless otherwise specified.
EXAMPLE 1
Fresh manure was collected by hand shovel from paved areas of a commercial beef cattle feedlot where the animals were fed a typical high-energy ration based on corn (Rhodes et al., Appl. Microbiol. 24: 3, 369-377, 1972). Collected waste (about 100 kg. per collection) was stored overnight at 4° C.
Raw waste (34.5% solids) was mixed with water to provide a mixture containing 22.1% solids which was stirred to a homogenous slurry. The FLW slurry was processed on a reciprocating screen as follows: A copper screen of 30 mesh (0.33 mm. wire, 0.59 mm. openings) was fastened over a rectangular wooden frame; an open three-sided wood frame was fastened on top of the screen frame to contain the slurry. The screen assembly was held tightly over a stainless steel tray which has separated openings at the lower end to discharge liquid and solids. The entire tray-screen assembly was held at 11° from horizontal and moves with a reciprocating motion through a 2-cm. displacement at ca. 300 strokes/minute when loaded. The screen was driven through a gear box and belt by a 1/4 h.p. electric motor. FLW ladled onto the high end of the screen traversed the length of the screen in about 1 minute under impetus of the screen motion. Liquid which separated from the waste through the screen drained from the receiving tray into a receiving vessel; fibrous solids migrated off the open lower end of the screen into a separate container. The FLW liquid (FLWL) containing 17.8% solids was stored at 4° C. in plastic containers until used. Fibrous solids were discarded.
Thirty-nine pounds of the FLWL was mixed with 50 pounds coarsely cracked corn having 10% moisture in a standard cement mixer having a 130-liter bowl (70 liter capacity). The mixer was belt driven through a reduction gear on a 1/4 h.p. electric motor so that the chamber rotated at 0.5 r.p.m. The interior of the mixer bowl (including mixing baffles) was sand blasted and painted with a two-component epoxy paint before use to eliminate rust formation from the acid fermentation. The bowl was held at 40° from horizontal. The mixer operated at ambient temperatures (18°-38° C.). The fermentation mixture was consistently 4° to 5° C. over ambient.
Fermentation was terminated after 36 hours, and the fermented product was dried in situ by blowing 60° C. air into the opening of the bowl while it continued to rotate. The fermented grain dried to a moisture content of 12% or less in 12-14 hours. Dried product dumped freely and was bagged and held for animal tests.
Analytical results were calculated to dry weight of fermented product. Moisture was determined by drying a weighed sample at 100° C. for 24 hours. Total nitrogen determined by micro-Kjeldahl was 2.68% for FLW and 1.33% for the corn (i.e., 17% and 8% crude protein, respectively). pH of fermented product was measured on a 5-g. sample triturated in distilled water for 10 minutes.
Microbial counts were done on material prepared by blending a 5-g. sample (wet weight) for 30 seconds in 20 ml. of cold 0.1 M phosphate buffer at pH 7 and then filtering and rinsing to volume through a loose fiberglass plug in a funnel. The turbid filtrate then was serially diluted in sterile distilled water. Counts were made by spread plating 0.3 ml. of appropriate dilutions in triplicate. Eugon agar was used for total counts and EMB for coliforms (both BBL, Bioquest Division of Becton, Dickinson Co.). Eugon plates were counted after 48-hour incubation at 28° C. and coliform counts were made after 24 hours at 37° C.
Ammonia determinations were performed on filtrates prepared with distilled water. Ammonia was measured with an ion-specific electrode (Orion Co., Cambridge, Massachusetts) on the supernatant of a blended sample centrifuged at 10,000 r.p.m. for 1 hour under refrigeration and reported as NH 3 -N, mg./g. dwb.
Results of the analysis of the above fermentation are tabulated in Table 1.
Table 1__________________________________________________________________________ Fermentation time, hoursAnalysis 0 12 24 36__________________________________________________________________________Moisture, % 42 42 41 41pH 6.31 4.63 4.37 4.21Ambient temperature, °C. 29 28 25.5 30Crude protein, % 10.3 10.2 10.2 10.1NH.sub.3 -N, mg./g., dwb 0.682 0.880 0.913 1.066Microbial pattern, counts/g., dwb Total 2.64 × 10.sup.9 2.30 × 10.sup.9 8.47 × 10.sup.8 1.39 × 10.sup.9 Coliform 1.70 × 10.sup.6 5.30 × 10.sup.6 3.10 × 10.sup.7 2.70 × 10.sup.7 Lactobacilli 1.47 × 10.sup.8 7.15 × 10.sup.9 3.97 × 10.sup.9 2.93 × 10.sup.9__________________________________________________________________________
EXAMPLE 2
Fresh cattle FLW having 42% solids was diluted with water to 24% solids and screened as described in Example 1. Thirteen pounds of FLWL (20% solids) and 13 pounds water were mixed with 50 pounds cracked corn (10% moisture, 8.0% crude protein) and fermented as described in Example 1.
Fermentation products were analyzed as described in Example 1 (Table 2).
EXAMPLE 3
Fresh cattle FLW having 34.5% solids was diluted with water to 22.1% solids and screened as described in Example 1. Thirty-six pounds of the FLWL (17.8% solids) were mixed with 50 pounds cracked corn (10% moisture) and fermented as described in Example 1. A fermentation typical of Example 1 resulted which had an initial pH of 6.1 and a final (30 hours) pH of 4.22.
EXAMPLE 4
Fresh cattle FLW having 26.0% solids was diluted with water to 18.6% solids and screened as described in Example 1. Seventeen and one-half pounds of the FLWL (16.5% solids) and 8 pounds water were mixed with 50 pounds cracked corn (10% moisture) and fermented as described in Example 1. A fermentation typical of Example 1 resulted which had an initial pH of 6.37 and a final (42 hours) pH of 4.28.
Table 2__________________________________________________________________________ Fermentation time, hoursAnalysis 0 6 12 24 36__________________________________________________________________________Moisture, % 38.7 38.7 39.0 39.3 37.0pH 5.39 5.20 4.67 4.01 4.01Crude protein, % 8.6 9.0 8.9 9.0 8.6NH.sub.3 -N, mg./g., dwb 0.168 0.159 0.164 0.189 0.208Microbial pattern, counts/g., dwb Total 2.78 × 10.sup.8 1.26 × 10.sup.8 1.97 × 10.sup.9 1.63 × 10.sup.9 8.65 × 10.sup.8Coliform 5.06 × 10.sup.6 6.53 × 10.sup.6 1.22 × 10.sup.6 1.24 × 10.sup.5 3.25 × 10.sup.5__________________________________________________________________________
EXAMPLE 5
Cracked corn (350 g., 10% moisture) and 175 g. fresh cattle FLWL prepared as described in Example 1 to contain 28% solids were mixed in 2-liter Erlenmeyer flasks. The flasks were held at 9° from horizontal on a board rotating at 0.6 r.p.m. Incubation was at 28° C. Two 5-g. samples were taken at 1, 6, 12, 24, 48, 72, and 144 hours. One sample was triturated in 10 ml. distilled water for 10 minutes and the pH measured before drying at 100° C. for 24 hours to give the dry weight. The second sample was blended with 20 ml. cold 0.1 M phosphate buffer (pH 7.0) for 30 seconds in a Waring Blendor, filtered through a loose glass-wool plug, and serially diluted (1:10) in 0.1% tryptone. Counts were made by spread plating 0.3 ml. of selected dilutions in triplicate.
The following media were used for counts: Eugon agar for total count, L and LBS agars for lactobacilli, Streptosel for total streptococci, KF Streptococcal with triphenyl tetrazolium chloride for fecal streptococci, Staphylococcus 110 for staphylococci, Eosin Methylene Blue (EMB) for coliforms, and Mycophil with added dihydrostreptomycin sulfate (0.2 mg./ml.), and penicillin G (330 units/ml.) for yeasts and molds. All media were BBL products (BBL, Division of Bioquest, Cockeysville, Maryland). EMB plates were incubated at 37° C. for 18 to 24 hours before counting; all other plates were counted after incubation at 28° C. for 2 days.
Apparent coliform colonies of the 24-hour sample were transferred from EMB plates to lactose broth and were examined microscopically. Colonies of lactobacilli from LBS and yeasts from Mycophil were transferred respectively to Micro Assay Culture Agar (BBL) and YM agar (Difco Laboratories, Detroit, Michigan). Isolates were incubated for 2 to 3 days at 28° C. before storing at 4° C. for subsequent examination. At each sample time, one to three plates of either the countable dilution or the next higher dilution were picked in entirety from LBS and from Mycophil (30 to 70 isolates per sample time).
A typical lactobacilli dominated fermentation resulted, Table 3.
EXAMPLE 6
Fresh cattle FLW was treated as described in Example 1 to produce a FLWL having 10% solids. The FLWL (225 g.) was mixed with 390 g. of cracked milo and fermented as described in Example 5. A typical fermentation resulted which had an initial pH of 5.35 and a final (72 hours) pH of 4.4
EXAMPLES 7-16
Fresh hog FLW collected from the Wayne Peugh farm, Dunlap, Illinois, was used in the fermentation without previous treatment. Suitable amounts of FLW, water, and cracked corn were mixed in a cement mixer and fermented as described in Example 1. Fermentation
Table 3__________________________________________________________________________ Fermentation time, hoursAnalysis 1 6 12 24 48 72 144__________________________________________________________________________pH 5.5 5.2 4.9 4.4 4.3 5.1 4.2Microbial pattern,counts/g., dwb Coliforms 7.2 × 10.sup.6 6.4 × 10.sup.6 5.9 × 10.sup.6 0 0 0 0 Lactobacilli 9.5 × 10.sup.6 2.6 × 10.sup.6 2.8 × 10.sup.8 2.6 × 10.sup.9 7.0 × 10.sup.8 2.1 × 10.sup.9 3.6 × 10.sup.9 Fecal streptococci 1.1 × 10.sup.5 1.8 × 10.sup.5 4.3 × 10.sup.5 2.7 × 10.sup.5 10.sup.3 10.sup.3 10.sup.2 Yeast 10.sup.4 10.sup.5 10.sup.6 2.1 × 10.sup.6 5.5 × 10.sup.6 9.5 × 10.sup.7 2.6 ×__________________________________________________________________________ 10.sup.7
conditions are listed in Table 4. Time of harvest was 36 hours, and the ambient temperature ranged from 18° to 38° C. Fermentation temperature was consistently from 3° to 5° C. higher than ambient. The initial fecal odor was always replaced by a silage-like odor soon after fermentation began.
Example 11 was sampled periodically during the fermentation, and the samples were analyzed for their microbial contents as described in Example 1. The microbial pattern is shown in Table 5.
EXAMPLE 17
Fresh hog FLW (200 g., 27% solids) was mixed with 125 ml. of water and 450 g. cracked corn (9.2% moisture) in a 2-liter flask and fermented and analyzed as described in Example 5. The unfermented corn contained 9.2% crude protein and the fermentation product contained 10.2% crude protein. Results of the analysis are shown in Table 6.
EXAMPLE 18
Products collected from several fermentations conducted as described in Example 5 were blended and offered to white Swiss mice in comparison to unfermented corn and a commercial pelleted diet. The fermented product and the unfermented corn were coarsely ground, cooked briefly in minimal amount of water to partially gelatinize the starch, and then formed into pellets. Each of the three diets was fed ad libitum for 21/2 months to six mice
Table 4__________________________________________________________________________Starting materialsFLW Corn Water pHExample Moisture, addedNo. Wt., lb. Solids, % Wt., lb. % Wt., lb. Initial At harvest__________________________________________________________________________7 10.0 29.1 50.0 12.9 24.0 6.4 4.58 15.0 29.9 50.0 12.9 15.0 5.8 4.69 20.0 29.9 50.0 12.9 13.5 5.3 4.610 19.5 24.5 50.0 8.8 15.1 6.0 4.711 25.0 21.8 50.0 13.1 7.1 7.2 5.112 25.5 19.0 50.0 9.0 8.5 6.2 --13 25.6 21.1 49.6 8.7 8.5 6.2 4.214 25.5 20.2 47.0 9.0 8.3 -- --15 28.0 22.2 50.0 13.1 4.9 -- 5.016 29.8 25.3 50.0 8.8 7.7 -- 4.6__________________________________________________________________________
Table 5__________________________________________________________________________Microbial patterncounts/g.,dwb Fermentation time, hours 0 6 12 24 30 36__________________________________________________________________________Total 3.2 × 10.sup.9 -- 1.1 × 10.sup.9 2.3 × 10.sup.9 -- 3.6 × 10.sup.9Coliform 0.9 × 10.sup.6 -- 1.9 × 10.sup.6 -- -- 1.4 × 10.sup.6Lactobacilli 1.6 × 10.sup.7 -- 2.9 × 10.sup.7 3.3 × 10.sup.9 -- 2.2 × 10.sup.9Yeasts 2.1 × 10.sup.5 -- 1.8 × 10.sup.3 1.5 × 10.sup.5 -- 3.9 × 10.sup.5__________________________________________________________________________
Table 6__________________________________________________________________________ Fermentation time, hoursAnalysis 0 12 24 36 48__________________________________________________________________________Moisture, % 38.9 38.0 40.2 39.6 40.2pH 5.95 4.88 4.61 4.50 4.50Crude protein, % 10.2 10.1 10.4 10.4 10.2NH.sub.3 -N, mg./g., dwb 0.144 0.177 0.160 0.169 0.202Microbial pattern, counts/g., dwb Total 1.4 × 10.sup.9 6.9 × 10.sup.8 1.2 × 10.sup.9 7.4 × 10.sup.8 3.2 × 10.sup.8 Coliform 7.0 × 10.sup.6 3.2 × 10.sup.5 5.0 × 10.sup.5 2.8 × 10.sup.6 3.9 × 10.sup.6 Lactobacilli 4.0 × 10.sup.7 6.0 × 10.sup.8 9.2 × 10.sup.8 6.5 × 10.sup.8 6.0 × 10.sup.8 Yeasts 2.8 × 10.sup.5 2.4 × 10.sup.5 4.7 × 10.sup.3 6.5 × 10.sup.3 4.0 × 10.sup.6__________________________________________________________________________
separated in cages of three segregated by sex. Mice were weighed every 3 or 4 days; weight data are shown in Table 7. The fermented product exhibited no overt toxicity to mice and consumption afforded equal growth rates compared to corn.
Table 7______________________________________ Days on diet, avg. weight in gramsDiet 1 10 21 42 74______________________________________Unfermentedcorn 14.7 15.6 17.6 20.0 23.3Fermentedcorn-FLWL 14.8 15.1 15.7 20.2 21.9Commercial feed 13.0 22.1 28.0 33.2 34.9______________________________________
EXAMPLE 18
Products (FG-FLW) from Examples 7 through 16 were combined and mixed in a twin shell blendor, mixed with hay, and fed to sheep in an acceptance-palatability test. Control sheep were fed a hay-cracked corn mixture. Acceptance and palatability were determined by measuring the total amount of feed unconsumed (weigh back) over a 10-day period (Table 8).
Table 8______________________________________ Hay, Cracked WeighControl g. corn, g. back, g.______________________________________2,841 3,000 8,800 1,4052,856 3,000 10,800 --2,868 3,000 10,400 3077,295 3,000 10,600 694Mean 3,000 10,150 602______________________________________ Hay, WeighExperimental g. FG-FLW, g. back, g.______________________________________2,848 3,000 10,800 52,854 3,000 10,800 --2,859 3,000 10,800 --7,294 3,000 10,800 61Mean 3,000 10,800 17______________________________________
EXAMPLE 19
The combined FG-FLW described in Example 18 was used to replace corn in a standard hen (control) diet (Table 9).
Table 9______________________________________Corn 63.15Alfalfa meal 5.00Soybean meal (44% C.P.) 19.00Meat and bone meal (49% C.P.) 2.00Solulac-500 (500 mcg.riboflavin/g.) 0.50Limestone 7.00Dicalcium phosphate 2.50Salt, plain 0.50DL-methionine (95% feedgrade) 0.10Vitamin-trace mineral premix(1552) 0.25______________________________________
Nineteen hens were fed the diet containing the FG-FLW mixture and 20 hens were fed the control diet. The feeding period was 21 days and feed consumption and egg production were measured during this time. The results are summarized in Table 10.
Table 10______________________________________ Feed consumed, Production, g./hen/day %______________________________________Control 116.4 31.2Experimental (Diet No. 2152 with 63.15% swine manure- corn replacing corn) 106.9 34.6______________________________________ | Feed grain compositions are prepared from grain and feedlot wastes by fermentation procedures which are carried out in simple equipment suitable for use on the feedlot site. The procedures are also suitable for industrial scale operations. Fecal odor of the waste is quickly eliminated and replaced by one that resembles the odor of silage. The fermented product has significantly more crude protein than corn, and it is palatable to livestock. | 0 |
FIELD OF THE INVENTION
The present invention relates to endotracheal tubes, and more particularly, to a device and method for facilitating the placement of an endotracheal tube within the trachea.
BACKGROUND OF THE INVENTION
Certain medical conditions can cause a patient's airway to become blocked, thereby preventing air from passing to the lungs. A commonly used therapy to treat a blocked airway involves inserting an endotracheal tube into the patient's trachea in order to restore airway patency. The insertion of the endotracheal tube into a patient's trachea is referred to as tracheal intubation.
In a tracheal intubation procedure, the endotracheal tube passes through a patient's mouth, through the larynx, and into the trachea. Once the endotracheal tube passes the larynx, it is difficult to properly align the tube into the trachea, because the inlets of the trachea and the esophagus are very close to each other, and the endotracheal tube is often inadvertently placed into the esophagus. Such misalignment significantly increases operating time and reduces the efficiency of the medical procedure. Such misalignment can also injure a patient by bruising the trachea and the esophagus tissues.
Various methods exist to facilitate the alignment of the endotracheal tube within the trachea. For example, a conventional method used to perform tracheal intubation is by direct laryngoscopy, in which a laryngoscope is used to visualize the patient's airway. In direct laryngoscopy, the laryngoscope is initially inserted into a patient's mouth. The patient's neck is then extended so that the inlet of the trachea can be visualized in order to facilitate the subsequent insertion of the endotracheal tube. Although direct laryngoscopy may be the most commonly used intubation technique, this method is cumbersome and poses a serious risk to patients that have neck injury.
SUMMARY OF THE INVENTION
The shortcomings and disadvantages of the prior art discussed above are overcome by providing an improved tracheal intubation device, which includes a endotracheal tube for insertion into a patient's body. More particularly, the endotracheal tube includes a tubular body, and primary and secondary cuffs attached to the tubular body. The secondary cuff is located proximal to the primary cuff. Both the primary cuff and the secondary cuff are inflatable from a collapsed position to an expanded position. As the secondary cuff inflates, the endotracheal tube is moved in an anterior direction toward the inlet of a patient's trachea. The tracheal intubation device also includes a stillette removably positioned within the tubular body and a guiding mechanism for guiding the stillette and the endotracheal tube within a patent's body. The guiding mechanism is positioned external to a patient and includes an indicator for indicating the location of the stillette. The guiding mechanism is sized and shaped so as to transmit a signal and to receive a signal indicating the location of the stillette in a patient's body.
A method is also disclosed for positioning the endotracheal tube within a patient's body. Initially, the endotracheal tube is inserted in a patient's body until a distal end of the endotracheal tube is positioned adjacent to the junction of the trachea and the esophagus. Then, the endotracheal tube is urged in an anterior direction toward the inlet of the trachea, which can be performed by inflating a secondary cuff on the tube. After the endotracheal tube is pushed toward the inlet of the trachea, the stillette is inserted into the trachea. Once the position of the stillette inside the trachea is confirmed by the guiding mechanism, the endotracheal tube is continually inserted until the distal end of the endotracheal tube is positioned within the trachea.
BRIEF DESCRIPTION OF THE DRAWINGS
For a more complete understanding of the present invention, reference is made to the following Detailed Description of the Invention, considered in conjunction with the accompanying drawings, in which:
FIG. 1 is a perspective view of a tracheal intubation device according to the present invention, which includes an endotracheal tube with primary and secondary cuffs, having a metal stillette inserted within the endotracheal tube, and an external guide system;
FIG. 2 is a perspective view of the endotracheal tube shown in FIG. 1 , which shows the primary and secondary cuffs in expanded configurations;
FIG. 3 is a schematic view of a patient's upper airway and the tracheal intubation device shown in FIG. 1 , which shows the endotracheal tube and the metal stillette aligned with a patient's mouth, and the external guide system attached to a patient's neck;
FIG. 4 is a schematic view similar to the view shown in FIG. 3 , where the endotracheal tube and the metal stillette have been advanced into the oropharynx;
FIG. 5 is a schematic view similar to that of FIG. 4 , where the second balloon has been inflated, causing the movement of the endotracheal tube and the metal stillette toward the inlet of the trachea;
FIG. 6 is a schematic view similar to that of FIG. 5 , where the metal stillette has been advanced into the trachea;
FIG. 7 is a schematic view similar to that of FIG. 6 , where the second balloon has been collapsed, and the endotracheal tube has been advanced further into the trachea; and
FIG. 8 is a schematic view similar to FIG. 7 , where the metal stillette has been withdrawn from the patient and the first balloon has been inflated.
DETAILED DESCRIPTION OF THE INVENTION
FIG. 1 illustrates a tracheal intubation device 10 that is used to facilitate ventilation in patients that have blocked airways. The tracheal intubation device 10 includes an endotracheal tube 12 , a metal stillette 14 , and an external guide system 16 . The endotracheal tube 12 includes an elongate tubular body 18 that has a distal end 20 and a proximal end 22 . The tubular body 18 can be made from any flexible material known in the art, such as plastic, silicon, and tygon.
With reference to FIGS. 1 and 2 , the endotracheal tube 12 further includes a primary cuff 24 attached to the tubular body 18 adjacent to the distal end 20 of the tubular body 18 . The primary cuff 24 includes a first inflatable balloon 26 , which extends about the entire circumference of the tubular body 18 . For reasons to be discussed hereinafter, the first balloon 26 is sized and shaped so as to inflate into a fully expanded configuration as shown in FIG. 2 and to deflate into a fully collapsed configuration as shown in FIG. 1 .
Referring to FIGS. 1 and 2 , a first inflating conduit 28 is provided for receiving air and vacuum. The first inflating conduit 28 has one end 30 connected to the first balloon 26 and an opposite end 32 connected to a luer lock connector 34 . The first inflating conduit 28 extends through an interior passageway 36 within the tubular body 18 , and includes an exterior portion 38 extending from the interior passageway 36 adjacent the proximal end 22 of the tubular body 18 . The air supplied via the first inflating conduit 28 can be used to inflate the first balloon 26 to its fully expanded configuration as shown in FIG. 2 , and the vacuum supplied via the first inflating conduit 28 can be used to deflate the first balloon 26 to its fully collapsed configuration as shown in FIG. 1 .
With continued reference to FIGS. 1 and 2 , the endotracheal tube 12 is also provided with a secondary cuff 40 positioned at a location proximal to the primary cuff 24 . The secondary cuff 40 includes a second inflatable balloon 42 , which is attached to the dorsal section 44 of the tubular body 18 and covers approximately half of the circumference of the tubular body 18 . For reasons to be discussed hereinafter, the second balloon 42 is sized and shaped so as to inflate into a fully expanded configuration as shown in FIG. 2 and to deflate into a fully collapsed configuration as shown in FIG. 1 . A second inflating conduit 46 is provided for receiving air and vacuum. The second inflating conduit 46 has one end 48 connected to the second balloon 42 and an opposite end 50 connected to a luer lock connector 52 . The second inflating conduit 46 extends through an interior passageway 54 within the tubular body 18 , and includes an exterior portion 56 extending from the interior passageway 54 adjacent the proximal end 22 of the tubular body 18 . The air supplied via the second inflating conduit 46 can be used to inflate the second balloon 42 to its fully expanded configuration as shown in FIG. 2 , and the vacuum supplied via the second inflating conduit 46 can be used to deflate the second balloon 42 to its fully collapsed configuration as shown in FIG. 1 .
Referring to FIG. 1 , the metal stillette 14 is shaped so as to be coaxially received within the tubular body 18 of the endotracheal tube 12 . The metal stillette 14 has a proximal end 58 and an enlarged spherical distal end 60 that has a diameter of about ¼ inch. The metal stillette 14 is covered with plastic or any other suitable biocompatible coating. The metal stillette 14 has a length in a range of from about 2 to about 2.5 feet and a diameter of about ⅛ inch. It should be understood that the above dimensions for the metal stillette 14 are merely exemplary and that the metal stillette 14 can have other dimensions.
The external guide system 16 (see FIGS. 1 and 3 - 6 ) is used to identify the position of the endotracheal tube 12 by identifying the location of the stillette 14 , from outside the body using various methods such as, for example, magnetic, electromagnetic, ultrasound, or capacitive sensing. As such, the external guide system 16 comprises an indicator 61 positioned outside the body to detect the position of a stillette. Metal detectors known in the art can be suitably modified for such a purpose. The external guide system 16 could include both a transmitter (not shown) for transmitting a signal and a receiver (not shown) for receiving a signal. A loudspeaker (not shown) and multiple light emitting diodes (LEDs) (not shown) can be provided within the external guide system 16 . A simple magnetic finder, like the type used to find studs in walls, i.e., a swiveling magnetic rod, could even be employed for the external guide system 16 . The finder could be placed at a patient's throat and the rod would point to the metal stillette 14 when the metal stillette 14 is positioned at the oropharynx.
In order to fully understand the advantages of the tracheal intubation device 10 , a brief overview of the throat 62 is discussed below with reference to FIGS. 3-7 . The structures of the throat 62 include the oropharynx 64 , the trachea 66 , and the esophagus 68 . The oropharynx 64 is located in the rear of the mouth 70 . The trachea 66 and the esophagus 68 , which is located dorsal to the trachea 66 , are situated below the oropharynx 64 .
In operation, prior to inserting the endotracheal tube 12 into a patient's throat 62 , the metal stillette 14 is placed within the endotracheal tube 12 such that the distal end 60 protrudes from the distal end 20 of the tubular body 18 and the proximal end 58 protrudes from the proximal end 22 of the tubular body 18 . The external guide system 16 is positioned at the anterior side of the patient's neck. The external guide system 16 can be retained in place by a strap around a patient's neck and can be placed at a 45 degree angle such that the transmitted and received signal of the external guide system 16 can be passed through the trachea 66 without interacting with the esophagus 68 .
The next steps, which are illustrated in FIGS. 3-7 , involve the insertion of the endotracheal tube 12 , along with the metal stillette 14 placed therein, into the throat 62 . With reference to FIGS. 3 and 4 , the endotracheal tube 12 is guided through the mouth 70 into the oropharynx 64 . Note that in the foregoing step, the first and second balloons 26 , 42 of the endotracheal tube 12 are both in their fully collapsed configuration in order to facilitate the insertion of the endotracheal tube 12 into the patient. In this position as shown in FIG. 4 , the distal end 60 of the metal stillette 14 is located adjacent to the junction between the inlet 72 of the trachea 66 and the inlet 74 of the esophagus 68 , while the second balloon 42 is in contact with the posterior wall 76 of the oropharynx 64 . When the endotracheal tube 12 and the metal stillette 14 reach this position, the position is detected by the external guide system 16 . Turning now to FIG. 5 , the second balloon 42 is fully inflated, via the second inflating conduit 46 , so as to assume its fully expanded configuration. As the second balloon 42 inflates, the contact between the second balloon 42 and the posterior wall 76 of the oropharynx 64 causes the endotracheal tube 12 , along with the metal stillette 14 placed therein, to move in an anterior direction such that the distal end 20 of the tubular body 18 and the distal end 60 of the metal stillette 14 are urged toward the inlet 72 of the trachea and away from the inlet 74 of the esophagus 68 .
The external guide system 16 can be used to align the metal stillette 14 toward the inlet 72 of the trachea 66 in the following manner. As previously indicated, the external guide system 16 senses the position of the metal stillette 14 . The external guide system 16 may emit a signal that passes through the trachea 66 and receives a signal that can be presented in the form of an audio and/or visual signal, which is used to determine the position of the metal stillette 14 . The intensity of the signal received by the external guide system 16 is indirectly proportional to the distance between the metal stillette 14 and the signal emitted by the external guide system 16 ; the intensity of the signal received by the external guide system 16 increases as the metal stillette 14 moves closer to the signal emitted by the external guide system 16 . If the metal stillette 14 is properly aligned with the inlet 72 of the trachea 66 , the intensity of the received audio signal will increase. This can be indicated by an audio or visual signal, which can appear on a display (not shown). If the metal stillette 14 is not properly aligned with the inlet 72 of the trachea 66 and is inadvertently advanced toward the esophagus 68 , the intensity of the received audio signal will decrease or become nonexistent, and/or the visual signal may not appear on the display. The absence of an audio signal or a visual signal will indicate incorrect placement of the metal stillette 14 , such as in the esophagus 68 . If improperly placed, the metal stillette 14 can then be manually moved to achieve proper alignment with the trachea 66 .
Once proper alignment between the metal stillette 14 and the inlet 72 of the trachea 66 has been achieved, the metal stillette 14 is manually pushed forward such that the distal end 60 of the metal stillette is advanced into the trachea 66 through the vocal cords, as shown in FIG. 6 . The external guide system 16 can be used to confirm that the metal stillette 14 has been placed into the trachea 66 . Once the metal stillette 14 is placed into the trachea 66 , the second balloon 42 is deflated into its collapsed configuration. Turning now to FIG. 7 , the endotracheal tube 12 is then pushed forward so as to advance toward the distal end 60 of the metal stillette 14 , which is positioned in the trachea 66 . Next, the metal stillette 14 is pulled out of the endotracheal tube 12 and withdrawn from the patient, as shown in FIG. 8 . The first balloon 26 is inflated, via the first inflating conduit 28 , so as to assume its fully expanded configuration. When expanded, the first balloon 26 serves to produce an air-tight seal in order to prevent upper airway obstruction and to prevent secretions from entering the lower tracheal regions.
It should be noted that numerous advantages are provided by the tracheal intubation device 10 of the present invention, and the above-described use of same to align the endotracheal tube 12 within the trachea 66 . For example, the second balloon 42 is utilized to align the endotracheal tube 12 with the inlet 72 of the trachea 66 . The external guide system 16 eliminates the need for a laryngoscope and the risks associated therewith. The metal stillette 42 provides rigidity to the endotracheal tube 12 . Accordingly, the second balloon 42 and the external guide system 16 each simplify the complicated task of aligning the endotracheal tube 12 within the trachea 66 . It should be understood that the present invention may be used to place the endotracheal tube 12 within the trachea 66 with the aid of the external guide system 16 , without the need to use the second balloon 42 . Likewise, the second balloon 42 can be used to move the endotracheal tube 12 toward the trachea 66 , without the need to use the external guide system 16 . The endotracheal tube 12 can even be placed in the trachea 66 without the need to use the metal stillette 14 .
It will be understood that the embodiment described herein is merely exemplary and that a person skilled in the art may make many variations and modifications without departing from the spirit and scope of the invention. For example, fluid rather than air can be used to inflate the first and second balloons 26 , 42 . The second balloon 42 could even be replaced with a mechanical device that expands a dorsal area of the endotracheal tube 12 when actuated. The second balloon 42 may employ the use of markers (not shown), such as radio-opaque markers. All such variations and modifications are intended to be included within the scope of the invention as defined in the appended claims. | The present invention relates to a tracheal intubation device and method for placing an endotracheal tube within a patient's trachea. More particularly, the endotracheal tube includes primary and secondary cuffs, in the form of inflatable balloons. A stillette is positioned within the endotracheal tube. The tracheal intubation device includes a guiding mechanism for guiding the stillette and the endotracheal tube within a patent's body. The guiding mechanism is positioned external to a patient and sized and shaped so as to transmit a signal and to receive a signal indicating the location of the stillette in a patient's body. After the endotracheal tube is positioned in the oropharynx, inflating the secondary cuff urges the endotracheal tube toward the trachea of a patient. | 0 |
RELATED APPLICATIONS
This application is related to provisional U.S. patent applications Ser. Nos. 60/129,955 and 60/134,664, filed Apr. 20, 1999 and May 18, 1999, respectively, both incorporated herein in their entirety by reference.
BACKGROUND
1. Field of the Invention
The present invention relates generally to implantable blood filters. More particularly, the invention relates to caval filters having sonographically conspicuous features.
2. Related Art
Advances in many surgical specialties have saved the lives of many patients suffering serious illness or injury, and have improved the quality of life of countless others. However, such surgical repair of organs and tissues can disrupt the body's plumbing, e.g., the circulatory system, sufficiently to give rise to new risks. For this reason, minimally invasive techniques have been developed, for example wherein highly specialized surgical tools are manipulated from outside a patient's body through a catheter or tube inserted through a tiny incision or puncture and guided to a surgical site. Yet, both invasive and minimally invasive procedures disturb circulation sufficiently so that arterial plaques can become dislodged or clots can form in the bloodstream and move with the circulation with the body. Such debris, moving along with normal circulation, can become lodged in and partially or completely block vessels supplying blood and oxygen to critical organs, such as the heart, lungs and brain.
Medication is often used to reduce the likelihood of blood clot formation during and after surgery, however, post-operative thrombosis, as such blood clot formation is called, remains an important problem to be solved. Therefore, filters implantable in a patient's body using minimally invasive techniques have been developed. By appropriately positioning such filters, dangerous blood clots can be removed from circulation and held in a safe location until they can be dissolved by medication or extracted, again using minimally invasive techniques. Thus, there has been a significant reduction in the incidence of morbidity and mortality due to post-operative embolism which occurs when a thrombolus moves from its site of formation to block a vessel, becoming an embolus.
Conventional implantable blood filters employing a variety of geometries are known. Many are generally basket or cone shaped, in order to provide adequate clot-trapping area while permitting sufficient blood flow. Also known are filters formed of various loops of wire, including some designed to partially deform the vessel wall in which they are implanted.
Along with their many functional shapes, conventional filters may include other features. For example, peripheral loops or arms may be provided to perform a centering function so that a filter is accurately axially aligned with the vessel in which it is implanted. In order to prevent migration under the pressure induced by normal circulation, many filters have anchoring features. Such anchoring features may include sharp points, ridges, etc. Finally, conventional filters are known which have specific features for facilitating implanting and extracting using catheterization. Thus, a surgeon can select from a variety of conventional filters, to optimize one or another parameter of interest, and implant or extract that filter using minimally invasive techniques.
The minimally invasive techniques mentioned above require that a surgeon guide a catheter to a precise location within a patient's body. The precise location within the body is visualized using conventional x-ray imaging and marked on the patient's body with marker or using x-ray fluoroscopy during surgery. The position of the catheter or other instrument within the body is visualized using similar techniques. As is well-known, x-rays, a form of ionizing radiation, produce an image showing by variations in image density corresponding variations in transmission density indicative of the position of various anatomical structures and of the instrument introduced into the body by the surgeon. In order to improve the fluoroscopic image of soft tissues, such as blood vessels, contrast media are sometimes introduced into a vessel to be imaged. An instrument which might otherwise be radiologically transparent may also be given a radiopaque tip or other feature. However, exposure to ionizing radiation or contrast media is contraindicated for a significant number of patients, such as pregnant women or patients exhibiting anaphylactic reactions to contrast media.
SUMMARY OF THE INVENTION
What is desired is a filter which is implantable in vivo in a human blood vessel, without the problems or disadvantages noted above.
In one embodiment, the invention may be realized in a filter, implantable in a blood vessel solely by sonographic visualization. Such a filter may include one or more wires arranged to trap blood clots without substantially interfering with normal blood flow; and an echogenic feature on at least one wire located in a position which during deployment of the filter remains fixed relative to one end thereof, so the filter position can be accurately determined solely by sonographic visualization. In such a filter, the echogenic feature may, for example, be a bead or a tube. When the feature is a tube, a marker wire may pass through the echogenic tube. The marker wire may include a plurality of echogenic markers, whereby correct visualization in a sonogram of a true longitudinal slice along the filter axis is readily ascertainable by presence in the sonogram of the tube in its entirety and each of the plurality of echogenic markers. Alternatively, depending on the design of the tube and its appearance in a sonogram, correct visualization in a sonogram of a true longitudinal slice along the filter axis is readily ascertainable by presence in the sonogram of the tube in its entirety.
Filters embodying the invention may be characterized by several different geometries. For example, in one geometry, one or more wires are arranged to define a cone-shaped basket attached to the echogenic feature at a vertex. The wire may be further arranged to define a substantially coplanar flower, the echogenic feature attached thereto at a center thereof. The cone and flower geometries may be combined, being joined by an outer ring of wire connecting a base of the cone to an outer position of the flower. The basket may be defined by substantially radially extending wires or by a mesh of wires extending in both radial directions and directions transverse the radial directions. Visibility using sonography of various geometries using the cone may be further enhanced by a plurality of echogenic markers substantially at a periphery of a base of the cone.
Filters embodying the invention may include other enhancements, as well. For example, the filter may include a plurality of loops of wire at a periphery of the basket, whereby the basket is axially aligned thereby during deployment thereof. The filter may also include a plurality of echogenic markers substantially at a periphery of the filter, whereby deployment thereof can be visualized.
According to another aspect of the invention, there is a method of implanting a blood filter in a blood vessel, comprising steps of: moving a blood filter having an echogenic feature located in a position which during deployment of the filter remains fixed relative to one end thereof through the blood vessel to an implantation site in the blood vessel; and during the step of moving, visualizing the echogenic feature of the filter and the implantation site sonographically. This method may be enhanced by adjusting a sonographic transducer to correctly visualize in a sonogram a true longitudinal slice along the filter axis, which is readily ascertainable by presence in the sonogram of at least one echogenic feature of the filter.
According to yet another aspect of the invention, a caval filter placement set includes a guide wire, a dilator, a sheath for introducing the filter, a caval filter including one or more wires arranged to trap blood clots without substantially interfering with normal blood flow, and an echogenic feature on at least one wire located in a position which during deployment of the filter remains fixed relative to one end thereof, so the filter position can be accurately determined solely by sonographic visualization. Moreover, the guide wire may be bent to facilitate locating a renal vein.
These and other features, objects and advantages of the invention will become apparent upon reading the following detailed description of some embodiments thereof, in connection with the drawings.
DESCRIPTION OF THE DRAWINGS
In the drawings, in which like reference designations indicate like elements:
FIG. 1 is a side view of one embodiment of a filter according to some aspects of the invention;
FIG. 2 is a top view of the embodiment of FIG. 1;
FIG. 3 is a side view of another embodiment of a filter according to aspects of the invention;
FIG. 4 is a top view of yet another embodiment of a filter according to aspects of the invention;
FIG. 5 is a side view of yet another embodiment of a filter according to aspects of the invention;
FIG. 6 is a top view of the embodiment of FIG. 5;
FIG. 7 is a side view of a modification of a conventional filter embodying aspects of the invention;
FIG. 8 is a side view of one embodiment of a filter according to some aspects of the invention;
FIG. 9 is a top view of the embodiment of FIG. 8;
FIG. 10 is a side view of one embodiment of a filter according to some aspects of the invention;
FIG. 11 is a top view of the embodiment of FIG. 10;
FIG. 12 is a side view of a bent guide or marker wire;
FIGS. 13 and 14 are side views showing placement of the bent guide wire in the vicinity of the renal veins within the vena cava;
FIG. 15 is a side view of an echogenic tube mounted over a guide or marker wire;
FIG. 16 is a sketch of a true sonographic image of an echogenic tube and guide wire; and
FIG. 17 is a sketch of an oblique sonographic image of an echogenic tube and guide wire.
DESCRIPTION
The present invention will be better understood upon reading the following description of several embodiments thereof, in connection with the drawings.
The present invention may be embodied in a set of devices for delivery of a caval filter to a desired position in a patient's body, preferably absent the use of fluoroscopic guidance. A caval filter embodying aspects of the invention is constructed of nitinol wire, in a form which is compact at room ambient temperature, but which expands to an operating configuration at a patient's body temperature. Alternatively, stainless steel, titanium, or other known materials implantable in the human body can be used. The filter includes a sonographically conspicuous feature at a distal, leading end thereof, by which the filter can be guided into position solely by use of sonographic imaging. As used herein, a sonographically conspicuous feature is one whose sonographic image, density, shape, etc. contrasts significantly with the image produced by other features. In order to improve the accuracy of positioning using the sonographically conspicuous feature at the distal end of the filter, the filter geometry and deployment apparatus is defined in such a way as to avoid foreshortening or other movement of the distal end of the filter during deployment. Also, sonographically conspicuous features may be included on the guide wire by which the filter is inserted and positioned in the patient's body.
Filters embodying the invention can also include sonographically conspicuous features located at the periphery of the filter. These features may be located at or near either end of the filter, depending on the design of the filter. Placing sonographically conspicuous features at the peripheral ends of the filter struts allows the opening of the filter to be observed using sonographic imaging only, if so desired. These peripheral, sonographically conspicuous features can mark the ends of filter struts or crossbars, as well as the ends of the filter. The ends of the filter can also be marked separately, as described above.
One type of sonographically conspicuous feature is one which is highly echogenic. A highly echogenic feature reflects a substantial portion of the ultrasound energy directed at it at a frequency of interest. A rough surface finish, having numerous acoustic interfaces, is more echogenic than a smoother surface finish. Also, a larger surface is more echogenic than a smaller one having a similar surface finish. Conventional bent-wire designs have been found not to be sonographically apparent.
Filters according to the principles of the present invention may be permanently implantable, e.g., having hooks to keep the filter in place, or may be removable, e.g., relying solely on pressure to keep the filter in place. Such filters can also have a variety of shapes suitable for their filtering purpose, as is known in the art. One preferred filter has an inverted cone-shaped basket at the proximal end thereof, for filtering. Some illustrative embodiments are now described in connection with the accompanying Figures.
The side view of FIG. 1 and the top view of FIG. 2 show one filter 101 having an echogenic feature located as described above. Three continuous strands of nitinol wire 103, 105, 107 form the illustrated filter 101. The upper strand 103 is coiled into an upper flower form having five loops 111. The lower strand 107 is coiled into a lower cone form, also having five loops 115. Finally, the middle strand 105 is coiled into an outer ring having ten loops, five directed up 109 and five directed down 113.
The upper loops 109 of the middle strand 105 join the loops 111 of the upper strand 103; the lower loops 113 of the middle strand 105 join the loops 115 of the lower strand 107. The lower cone formed by the lower strand 107 has a vertex 117 joined to the center 119 of the upper flower formed by the upper strand 103 at weld 121. Weld 121 defines an echogenic bead 123. Preferably weld 121 has a diameter of 2 mm, although the diameter may also be as small as about 1 mm or even as large as about 3 mm. The diameter should be sufficient to define the echogenic bead 123 so as to provide adequate sonographic conspicuousness.
Filter 101 of this embodiment is preferably about 3 cm long and about 3 cm in diameter when fully expanded. In use, the filter may not expand fully, slight compression holding it in place where the surgeon desires.
Various alternative filter design features are now described in connection with FIGS. 3-7. These figures show various features which can be combined in numerous other permutations and combinations than shown, as will be apparent to those skilled in this art.
The side view of FIG. 3 shows alternative configurations for an echogenic feature and for centering features. In this alternative configuration, an echogenic tube 301 supports individual wire strands 303 arranged as a cone filter. Wire strands 303 further support individual centering loops 305. The components are welded or brazed together using conventional techniques. Echogenic properties are imparted to the tube 301 by virtue of its size and surface finish, as described above. In preferred configurations using an echogenic tube 301, the tube 301 has an inside diameter large enough to freely pass a 0.035 inch (0.89 mm) diameter guidewire. Also preferred in some configurations, the tube 301 has a flared, dilated or contracted feature 307 at one end to facilitate gripping of the tube 301 for purposes of removing the filter after it has served its purpose.
Although FIGS. 1-3 show filter wires (e.g., 107, 303) which are generally straight or smooth curves, as shown in FIG. 4, bent filter wires 401 can reduce the size of openings between wires, resulting in a more effective filter, without blocking the free flow of normal blood.
FIGS. 5 and 6, side and top views, respectively, illustrate a configuration employing an echogenic tube 301, as described above, to which straight filter wires 501 are conventionally welded or brazed. Instead of centering loops 305, this configuration has a split side ring 503 to prevent filter migration, once placed where desired by the surgeon. Spring pressure pushes the split side ring 503 into the vessel wall when the filter is in the position desired, thus anchoring the filter against the pressure of blood flow through the filter. Gaps 505 between segments of the split side ring 503 allow the filter to be compressed to a smaller diameter than when deployed for insertion, removal or positioning within a vessel of a patient's body. Instead of straight filter wires 501, this configuration can use bent filter wires 401, as in the configuration of FIG. 4. The echogenic tube 301 can have the characteristics and features described above in connection with FIG. 3, if desired.
A modification of a conventional filter design made by MediTech, Boston Scientific (Natick, Mass.) is illustrated in the side view of FIG. 7. In this configuration, filter 701 includes an echogenic tube 301 not found in the conventional MediTech design. The echogenic tube 301 of this configuration also may include the features described above, such as the extraction feature 307.
Yet another filter configuration is shown in FIGS. 8 and 9 in side and top view, respectively. The filter 800 shown has a central echogenic tube 301, supporting a plurality of bent wires 801, 803. Bent wires 801 are arranged as one filter cone, while bent wires 803 are arranged as a second filter cone. Bent wires 801 and 803 are connected together through straight wires 805 and a split side ring 503, similar to that described above in connection with FIGS. 5 and 6.
Finally, a simple filter is shown in FIGS. 10 and 11 in side and top view, respectively. This filter 1001 also has a central echogenic tube 301, supporting a plurality of wire legs 1003. Wire legs 1003 each have a radially extending portion 1005, arranged to form a filter cone, and a longitudinally extending portion 1007. The longitudinally extending portion 1007 centers and axially aligns the filter with the axis of the vessel in which it is to be implanted, similar to the action of centering loops 305 and the middle strand 105 of the above described embodiments. The longitudinally extending portions 1007 end in loops 1009 and points 1011, which securely anchor the filter in the vessel in which it is implanted.
Filters embodying aspects of the invention are generally used in the same manner as other filters used in this art. However, the imaging used in connection with embodiments of the invention can be sonographic, rather than fluoroscopic.
The invention can be embodied in a complete set using any of the above-described filters or variations. The set employs a #7 or #8 French dilator having an echogenic tip. The set further includes a #8 French sheath, also having an echogenic tip, of flexible plastic. Finally, the set is guided by a 0.035 inch (0.89 mm) diameter guide or marker wire having one or more, preferably three, echogenic sites at or near the distal end thereof. The guide or marker wire may be a straight wire or a curved wire, as described below in connection with FIGS. 12-14. The set thus described can be used to implant a filter using only external sonography or a combination of external sonography with other techniques, as described below. Although components of the set may be separately available, it is expect that the dilator, sheath, guide wire end filter will be supplied as a complete set also, for convenience and consistency.
Delivery and deployment of a filter, e.g., FIG. 1, 101, having an echochenic lead 123, below the renal veins proceeds as follows.
The locations of the renal veins are determined and marked on the skin with marker, using any conventional means. This may include the techniques for internal sonography described by Bonn et al., Intravascular Ultrasound as an Alternative to Positive-contrast Vena Cavography prior to Filter Placement, Journal of Vascular Interventional Radiology, Vol. 10, No. 7, pp. 843-849, 1999. Alternatively, external sonography can also be used to locate the renal veins.
As shown in FIGS. 12-14, a curved guide wire 1201 having a series of sonographically conspicuous features 1203, for example 3-12 features spaced about 1 cm apart, is then inserted to a point just past the confluence 1205 of the renal veins 1207 forming the vena cava 1209, and then withdrawn to engage one renal vein 1207. Once the wire 1201 engages the renal vein 1207, slight advancement anchors the renal vein 1207. The progress of the curved, sonographically conspicuous wire 1201 is easily followed using external sonography.
The guide wire, particularly the curved guide wire 1201 introduced as described above, and the echogenic features of the guide wire make possible very precise identification using external sonography of the desired placement location. The dilator is then introduced over the guide wire and the echogenic tip thereof is also followed by external sonography to the filter placement location. Finally, the filter, contained in the end of the sheath, is guided over the guide wire, inside of the dilator, to the placement location and deployed. The precise location of the filter is followed using external sonography.
The filters described above are very flexible, having low profiles, i.e., small undeployed diameters and short lengths, permitting access to the patient's venous system through various conventional locations, including the jugular vein, the groin vein, etc. Moreover, because the filter features avoid foreshortening of the filter relative to the distal end thereof, highly accurate tracking and placement is achieved by simply visualizing the distal end of the filter as it progresses to the placement location.
Delivery and deployment of a filter below the renal veins with an echogenic tube 301 instead of or in addition to an echogenic lead 123 proceeds in similar fashion, but with some advantages now described in connection with FIGS. 15-17. Principally, when using a filter configured with an echogenic tube 301, or other configuration of sonographically conspicuous features which are aligned to show the axial alignment and position of the filter, the filter can be slid over a marker wire 1501, as generally shown in FIG. 15 while the true longitudinal position and axial orientation of the filter is correctly visualized.
As shown in the sonographic image sketched in FIG. 16, when the sonographic beam is aligned with the tube 301 and the marker wire 1501, a true image 1601 is obtained, and the true longitudinal and axial position can be determined from the angle of incidence of the beam and the depth of the tube 301 and wire 1501 within the true image 1601. The true image 1601 of FIG. 16 is contrasted with the oblique image 1701 of FIG. 17, in which incomplete information is available. In this oblique image 1701, the angle of incidence of the beam is turned slightly, so that only a portion of tube 301 and marker wire 1501 are each visible in the oblique image 1701. When such an oblique image 1701 presents itself, the surgeon guiding the filter including tube 301 can determine whether the visible portion of tube 301 represents the distal or proximal end of the filter and either guide the filter accordingly or adjust the sonogram beam or the filter position to obtain a true image 1601.
It is expected that struts, and other filter parts which do not specifically include sonographically conspicuous features will be difficult or impossible to see, while the tube 301 will be easily seen. Thus, the tube 301 and marker wire 1501 combine in the image to permit optimum sonographic imaging to be arranged.
The overall filter and placement set and procedures described above permit filter placement by a physician at bedside, in an office (as compared to hospital) setting, or in a sonographic suite. Thus, the need for a fluoroscopic suite or equipment is obviated by the inventive filters, placement sets and methods. The inventive filters, placement sets and methods are also appropriate for intraoperative placement where fluoroscopy is not available, cumbersome, inappropriate or otherwise untenable due to operating room facilities, availability, required procedures or contraindication of any other kind.
When desired, the filters and methods of the present invention can be assisted by magneto-resonant (MR) and computed tomography (CT) visualization methods. Such methods are particularly suitable when the filter is constructed of nitinol or another material which shows up in an MR or CT image. Fluoroscopic assistance can also be used with nitinol filter structures, as well as other materials which show up in a fluoroscopic image. A highly visible marker wire may also be helpful to these methods.
The invention has now been shown and described in connection with an embodiment thereof and some variations, but the invention is not limited thereto. Other variations should now be evident to those skilled in this art, and are contemplated as falling within the scope of the invention which is limited only by the following claims and equivalents thereto. | A vena cava filter and placement set includes features which can be visualized solely utilizing sonography. A method of implanting a vena cava filter employs sonography to enable the surgeon to direct the filter to a desired location and ensure that the filter is properly deployed. | 0 |
BACKGROUND OF THE INVENTION
I. Field of the Invention
The invention relates to a method and apparatus for conducting wireline operations in oil and gas wells under blowout conditions, and includes a releasable annular wireline blowout preventer.
II. Description of the Prior Art
It is frequently necessary to periodically introduce various cable, or wireline, suspended well tools or instruments into open hole or producing oil or gas wells. Where a well is producing or is an open hole well and contains well fluids such as drilling mud at high pressures, the upper end of the well casing is closed by suitable valving apparatus and special well-servicing equipment must be provided to safely introduce and remove such wireline tools or instruments.
In performing wireline operations for wells under pressure, it is required that the well pressure be controlled during such operations. It must be possible to: lower the wireline suspended tool into the well; perform the conventional wireline operations, such as well logging or perforating operations; and recover the wireline suspended tool, while the well remains sealed. Since all wireline operations involve a moving wireline, or cable, a seal must be provided to prevent well fluid or gas from escaping from the well, while simultaneously allowing free movement of the cable. Furthermore, although an uncased well is normally held under pressure control by drilling mud present in the well, occasionally the pressure forces become unbalanced and the well blows out. Because of such potential emergency situations caused by excessive pressure buildup, or blowout conditions within the well, it is necessary to provide the well with pressure control equipment to quickly allow the well to be sealed when such blowout conditions are encountered and thereafter safely recover the wireline suspended tool.
Accordingly, conventional oil and gas wells which include a main cut-off valve on the wellhead have been provided with a blowout preventer temporarily connected to the cut-off valve on the wellhead. To such blowout preventer, a riser comprising one or more lengths of pressure-control pipe is installed. The riser is sealed at its upper end by a stuffing box, or line wiper, to provide a pressure seal around the wireline at the point where the wireline exits from the riser.
In this manner, when the main wellhead cut-off valve is closed, the wireline suspended tool can be safely inserted into the riser. The wireline is then passed through the stuffing box which is then sealed about the wireline. After the main cut-off valve is opened, the wireline suspended tool is lowered through the open blowout preventer and on into the well. Representative examples of such devices and methods of operation may be found in U.S. Pat. Nos. 3,416,767, issued to L. Blagg and 3,887,158, issued to J. Polk.
In each of the foregoing patents, pressure control at the wellhead during the performance of wireline operations is provided by: a blowout preventer, or wireline valve, provided above the main cut-off valve; a long length of riser attached to the blowout preventer; and a stuffing box provided at the upper end of the riser.
Although such devices and methods of operation provide a means of removing wireline tools from an oil well under blowout conditions, without compromising established safety practices, such devices and method of operation require a great amount of equipment. This equipment must always be installed at the wellhead prior to the time when wireline operations are commenced in order to assure that the well may be controlled during emergency blowout conditions. Most of the time, the installation of such equipment is unnecessary especially in open-hole wells where most wells remain under control and blowout conditions are not encountered.
In particular, before conducting wireline operations, a great length of pressure-control pipe must always be installed, the length of the riser being dependent upon the length of the wireline suspended tools which must be accommodated within the long riser. Such long riser equipment is large, heavy, and requires considerable time to install, operate, and remove from the well after completion of wireline operations. Furthermore, the ram-type blowout preventers utilized beneath the long riser cannot be used to provide a seal about a moving wireline; however, they can be used to provide a seal about a wireline under static conditions. Consequently, the additional wireline stuffing box must be provided at the end of the riser to seal about moving wireline cables. Moreover, such ram-type blowout preventers, which are capable of allowing the through passage of wireline suspended tools, such as logging tools, are large, heavy, and bulky--thus presenting equipment handling problems at the wellhead.
Accordingly, prior to the development of the present method and apparatus, there has been no method or apparatus for conducting wireline operations in oil and gas wells under blowout conditions which: is efficient to install, operate, and remove; requires a minimum amount of equipment to be installed prior to performing wireline operations under normal conditions thereby greatly facilitating wireline operations on the large majority of wells for which blowout conditions are not encountered; provides a seal on a moving wireline; is economical; is safe in its operation; and does not require large, heavy, and bulky ram-type blowout preventers. Therefore, the invention provides a long sought efficient, safe, and less costly method and apparatus for conducting wireline operations in oil and gas wells, particularly uncased wells which may be subject to blowout, or other emergency, conditions.
SUMMARY OF THE INVENTION
In accordance with the invention, the foregoing benefits have been achieved through the present method and apparatus for conducting wireline operations in oil and gas wells under blowout conditions. The apparatus for conducting such wireline operations is a releasable annular wireline blowout preventer for use with oil and gas wells during wireline operations. It includes: an annular body having upper and lower ends, and an inner diameter capable of allowing the through passage of a wireline suspended tool; first means for attaching the annular body to a first riser, or directly to the well head cut-off valve, said first attachment means associated with the lower end of the annular body; second means for attaching the annular body to a second riser, said second attachment means associated with the upper end of the annular body; a wireline seal assembly means for preventing well fluid leakage about the wireline; said annular body having selective engaging means for securing the seal assembly means within the annular body during normal wireline operations; and means for releasing said selective engaging means to allow the removal of the seal assembly means upwardly through the annular body, whereby during wireline operations under blowout conditions the seal assembly means and wireline suspended tool may be both removed through the annular body and into the second riser.
A feature of the present apparatus is the annular body being provided with means for equalizing pressure differences between the first and second risers. Further features of the apparatus of the present invention include means for locking the annular body to the first riser, and the wireline seal assembly means may include a hydraulically actuated resilient member which is compressed along and about the wireline upon actuation.
Additional features of the apparatus of the present invention are that the lower portion of the wireline seal assembly means includes a guide receptacle for the wireline suspended tool, and the selective engaging means may include at least two bolts, threaded in the annular body which, upon being rotated, contact the wireline seal assembly means.
The method of the present invention for conducting wireline operations in oil and gas wells and for removal of wireline suspended tools during blowout conditions in the well is used with a well provided with some type of main cut-off valve. The method comprises the steps of: fixedly securing an annular body to the top of a first riser associated with the cut-off valve, or directly to the cut-off valve, said body having an inner diameter capable of allowing the through passage of a wireline suspended tool; opening the cut-off valve; lowering a wireline suspended tool through said annular body, first riser, and cut-off valve, said wireline suspended tool having a wireline seal assembly means disposed about the wireline; securing the wireline seal assembly means within the annular body; and readying the second riser for attachment to the annular body in the event of possible blowout conditions. In the event of blowout conditions the method further comprises the steps of lowering the wireline suspended tool into the well; sealing the wireline seal assembly means about the wireline upon encountering blowout conditions in the well; passing a portion of the wireline which is disposed outside the well and wireline seal assembly means through a second riser having a stuffing box disposed in the upper end of the second riser; attaching the lower end of the second riser to the top of the annular body and sealing the stuffing box about the wireline; equalizing the pressure between the first and second risers; releasing the wireline seal assembly means from the annular body; raising the wireline suspended tool and wireline seal assembly means into the second riser and past the cut-off valve; and closing the cut-off valve to seal the well.
A feature of the foregoing method of the present invention includes the step of cutting the wireline prior to passing the wireline through the second riser.
Additional features of the foregoing method include the steps of releasing the pressure within the second riser after the cut-off valve is closed to seal the well, and dismantling the second riser, annular body, wireline suspended tool, and wireline seal assembly means from one another.
A further feature of the foregoing method of the present invention includes the step of raising the wireline suspended tool to a position adjacent the cut-off valve after blowout conditions are encountered in the well.
Another feature of the method of the present invention includes the step of attaching a second riser to the top of the annular body, whereby the length of the first and second riser is sufficient to enclose the wireline suspended tool.
The method and apparatus of the present invention for conducting wireline operations in oil and gas wells under blowout conditions, when compared with previously proposed prior art methods and apparatus have the advantages of: safety, ease of installation, operation, and removal; being less costly to manufacture and use; requiring only a minimum amount of equipment to be initially installed on the wellhead, thereby greatly facilitating wireline operations for the large majority of wells for which blowout conditions are not encountered; not requiring the use of a large, heavy and bulky ram-type blowout preventer; and can be used to provide a seal against leakage of well fluid from about a moving wireline.
BRIEF DESCRIPTION OF THE DRAWINGS
In the drawings:
FIG. 1 is an enlarged cross-sectional view of the releasable annular wireline blowout preventer of the present invention, wherein the wireline seal assembly means is secured within the annular body;
FIG. 2 is a cross-sectional view of the releasable annular wireline blowout preventer of the present invention and illustrates the wireline seal assembly means prior to its being inserted in the annular body;
FIG. 3 illustrate details of an alternative means for securing the wireline seal assembly means in the annular body;
FIG. 4 is a cross-sectional view of the releasable annular wireline blowout preventer, illustrating certain steps of the method of the present invention for conducting wireline operations under blowout conditions;
FIG. 5 is a cross-sectional view further illustrating the method of the present invention for conducting wireline operations in oil and gas wells under blowout conditions and,
FIG. 6 is an enlarged cross-sectional view of the releasable annular wireline blowout preventer of FIG. 1, wherein another selective engaging means for the wireline seal assembly means is shown.
While the invention will be described in connection with the preferred embodiment, it will be understood that it is not intended to limit the invention to that embodiment. On the contrary, it is intended to cover all alternatives, modifications, and equivalents as may be included within the spirit and scope of the invention as defined by the appended claims.
DETAILED DESCRIPTION OF THE INVENTION
In FIG. 1, an enlarged cross-sectional view is shown of the new and improved releasable annular wireline blowout preventer 50 of the invention. The releasable annular wireline blowout preventer 50 includes: an annular body 51 having upper and lower ends 52 and 53; a wireline seal assembly means 54; a first means for attaching the annular body 51 to a first riser, or length of pressure control pipe 55, said first means for attaching shown generally at 56 and is associated with the lower end 53 of the annular body 51. The annular body 51 may alternatively be attached directly, or via an integral annular extension, to the wellhead cut-off valve 93. The releasable annular wireline blowout preventer 50 also has associated with the upper end 52 of annular body 51, a second means for attaching the annular body 51 to a second riser, to be hereinafter described. The second attachment means is generally indicated at 57 and is associated with the upper end 52 of annular body 51.
Still referring to FIG. 1, it is seen that annular body 51 has selective engaging means 58 for securing the wireline seal assembly means 54 within annular body 51. The releasable annular wireline blowout preventer 50 is further provided with a means for releasing 59 the selective engaging means 58 from wireline seal assembly means 54. A conventional wireline 60, or flexible cable, passes through wireline seal assembly means 54. Attached to wireline 60 is a conventional wireline tool, as will be hereinafter described.
The releasable annular wireline blowout preventer 50 of the present invention will now be described in greater detail, while still referring to FIG. 1. Preferably, the first attachment means 56 for securing annular body 51 to the first riser 55 is internal threads 61 disposed on the interior of annular body 51 at its lower end 53. Threads 61 engage with the external threads 62 formed on the top outer surface of first riser 55. Annular body 51 could also be threadedly received within first riser 55 via external threads on annular body 51 which mate with internal threads formed at the top inner surface of first riser 55. Likewise, annular body 51 could be attached to first riser 55 via a flange connection, including an O-ring, or other suitable sealing means, or by any other suitable type of connection which would provide a fluid tight connection between first riser 55 and annular body 51. In this regard, annular body 51 is provided with an O-ring 63 for providing a fluid tight seal between the top of first riser 55 and annular body 51. Preferably, O-ring 63 is positioned in an annular groove 64 formed in the interior surface of annular body 51.
The releasable annular wireline blowout preventer 50 may also be provided with a means for locking the annular body 51 to the first riser 55, such locking means being generally shown at 65. Locking means 65 may preferably comprise one or more threaded bolts 66 which may be threaded through annular body 51 into engagement with the lower portion of external threads 62 of riser 55 as shown at 67.
Wireline seal assembly means 54 is seen in FIG. 1 to include a generally annular shaped body member 68 which includes an outwardly extending annular rib 69 which will be hereinafter described. The upper end of the annular body member 68 of wireline seal assembly means 54 is suitably closed at 70 as is the lower end of annular body member 68 closed at 71. Disposed within the interior of annular body member 68 of wireline seal assembly means 54 is an annular resilient bladder member 72, and another annular resilient member 73 is concentrically disposed about wireline 60, and is positioned between wireline 60 and bladder member 72. Annular resilient members 72 and 73 may be made of any suitable material having the requisite elastic capabilities to be deformed under pressure and assume its former shape after such pressure is released. Annular resilient member 73 must also have the ability to withstand exposure to well fluids which may be on the surface of wireline 60. Examples of such a material would be rubber, or other synthetic elastormeric materials having the foregoing qualities.
Annular body member 68 of wireline seal assembly means 54 also includes a hydraulic fluid passageway 74. Passageway 74 is preferably disposed between an annular groove 75, formed in the interior surface of body member 68, and the outer surface 76 of annular body member 68 of wireline seal assembly means 54.
Still referring to FIG. 1, it is seen that the interior surface of annular body 51 may be provided with a plurality of grooves 77 which contain O-rings 78 for providing a fluid tight seal between the outer surface 76 of annular body member 68 of wireline seal assembly means 54 and the interior surface 79 of annular body 51. Annular body 51 is also provided with a suitable connection shown generally at 80 for allowing a hydraulic hose 81 to be attached in fluid transmitting relationship to passageway 74 and annular groove 75 in body member 68 of wireline seal assembly means 54, as will be hereinafter described in more detail. The lower portion 71 of wireline seal assembly means 54 may also be provided with a guide receptacle 82 for the wireline tool suspended from wireline 60, as will also be hereinafter described.
As shown in FIG. 1, annular body 51 is provided with a suitable valve 83 which is disposed in fluid transmitting relationship with the interior of riser 55, as shown generally at 84, when annular body 51 is attached to riser 55. The function of valve 83 will be hereinafter described.
Selective engaging means 58 is generally shown to be one or more bolts 85, (preferably two) each having a threaded portion 86 received within annular body 51 and a generally smooth end portion 87 which contacts and rests upon the annular rib 69 formed on the outer surface of annular body member 68 of wireline seal assembly means 54. Upon inward movement caused by rotation of bolts 85, wireline seal assembly means 54 is secured within annular body 51. Selective engaging means 58 may also include an annular flange 88 disposed toward the middle of bolts 85, whereby O-rings 89 may be mounted about the portion of bolts 85 located between threads 86 and flange 88. Accordingly, upon rotation of bolts 85 as their end portions 87 contact the wireline seal assembly means 54, the O-rings 89 are compressed between the flanges 88 and the annular member 51, in order to provide a fluid tight seal between bolts 85 and annular member 51.
The outwardly extending head portions 90 of bolts 85 provide a means for releasing selective engaging means 58 and its smooth end portion 87 from the annular rib 69 of wireline seal assembly means 54. The releasing means 59, or bolt heads 90, may be rotated by means of a suitable wrench, as is readily apparent. Of course, other structures 58' and 59', as shown in FIG. 6, could be used for selective engaging means 58 and its releasing means 59, such as by substitution of at least one or more (preferably two or more) hydraulically operated piston members 85' (FIG. 6) which would have end portions 87' similar to end portions 87 of bolts 85 shown in FIG. 1. Upon hydraulic actuation of such piston members 85' via the fluid in hoses 110 (only one of which is shown for clarity in FIG. 6), their end portions 87' would engage annular body member 68 of wireline seal assembly means 54 above the annular rib 69 of body member 68. The releasing means 59' in FIG. 6 is provided by hydraulic actuation of piston members 85' via the fluid in hoses 90' (only one of which is shown in FIG. 6 for clarity). Piston members 85' are provided with suitable O-rings 89' to effect sealing as is well known in the art, and piston members 85' also include flanges 88' as previously described with reference to flange 88 of FIG. 1. It should be noted that both selective engaging means 58 and 58' cooperate with body member 68 of wireline seal assembly means 54 to preclude upward movement of the wireline seal assembly means 54 within annular body 51. Wireline seal assembly means 54 is precluded from downward movement within annular body 51 by the engagement of annular rib 69 with an interior ledge, or rib, 91 formed in annular body 51, as seen in FIG. 1.
Referring now to FIGS. 1 and 2, the annular body 51 of releasable annular wireline blowout preventer 50 of the present invention is shown attached to the first riser 55, which is in turn attached, as at 92, to a conventional wellhead cut-off valve 93. As illustrated, riser 55 is threadedly received at 92 into cut-off valve 93; however, first riser 55 could be attached to cut-off valve 93 in any other suitable manner, such as by a flange connection. Cut-off valve 93 is generally shown to include two hydraulically actuated piston members 94 and 95, which may be activated to completely seal the well. For illustration purposes, cut-off valve 93 is threadedly received about conventional well casing 96, as shown in FIG. 2, although other conventional valving equipment could be disposed at the wellhead between valve 93 and casing 96.
As shown in FIG. 2, a conventional wireline tool 97 is shown attached to wireline 60 by a conventional wireline cable head 98. Wireline cable head 98 is received within the guide receptacle 82 disposed at the lower end 71 of wireline seal assembly means 54. As seen in FIG. 2, annular body 51 of releasable annular wireline blowout preventer 50 has an inner diameter capable of allowing the through passage of the conventional wireline suspended tool 97. Accordingly, as shown in FIG. 2, the wireline suspended tool 97 with wireline seal assembly means 54 resting upon cable head 98, may be lowered downwardly through annular body 51, riser 55, and cut-off valve 93 into well casing 96.
As seen in FIGS. 1 and 2, a conventional wireline guide 99 is mounted on the upper portion of wireline seal assembly means 54, and is concentrically mounted about wireline 60. Although the construction of body member 68 of wireline seal assembly means 54 in FIG. 1 discloses the use of an annular rib 69 which is contacted by selective engaging means 58, an alternative construction is shown in FIG. 2. As seen in FIGS. 2 and 3, body member 68 of wireline seal assembly means 54 is provided with at least two slotted portions 100 and 100' formed on the outer surface 76 of annular body member 68. FIG. 3 illustrates wireline sealing assembly means 54 rotated 90 degrees from the position of FIG. 2 to show the construction of slotted portions 100' and 100 in annular rib 69'. Thus, in the embodiment of FIGS. 2 and 3, the outer surface 76 of annular body member 68 of wireline sealing assembly means 54 is provided with a rib 69' with at least one or more pairs of slots 100' and 100 formed in the rib 69'. Slots 100' and 100 are adapted to mate with the end portions 87 of selective engaging means 58 which extend into the interior of annular body 51. Upon the downward movement of sealing assembly means 54 in relation to annular body 51, smooth end portion 87 passes through slotted portion 100'. Upon radial movement of sealing assembly means 54 slot 100 comes to engage smooth end portion 87 thereby preventing upward movement of sealing assembly means 54. Of course, the number of slotted portions 100 and 100' in annular rib 69' will correspond to the number of selective engaging means 58 provided in annular body 51.
Turning now to FIGS. 2, 4 and 5 the operation of the releasable annular wireline blowout preventer 50 and the method steps of the present invention will be described. As shown in FIG. 2, a first riser 55 has been attached to cut-off valve 93, and annular body 51 has been attached to first riser 55 by use of the first attachment means 56. At this time hydraulic hose 81 may be connected to annular body 51 at connection 80, and locking means 65, or threaded bolts 66 may be rotated to engage riser 55 to further secure annular member 51 to riser 55. After cut-off valve 93 is opened, wireline suspended tool 97 is lowered through annular body 51, first riser 55, and cut-off valve 93. As seen in FIG. 2, wireline suspended tool 97 has wireline seal assembly means 54 disposed about the wireline 60, as the wireline suspended tool 97 is lowered.
After wireline seal assembly means 54 has been lowered into annular body 51 as depicted in FIG. 1, the wireline seal assembly means 54 is secured within annular body 51 by selective engaging means 58. The end portions 87 of selective engaging means 58 contact the rib portion 69' or 69 of the body member 68 of wireline seal means 54, thus securing the wireline seal assembly means 54 within annular body 51.
Now, normal wireline operations using wireline suspended tool 97 may be conducted by lowering wireline suspended tool 97 into the well casing 96 of the well. As wireline 60 moves downwardly into well casing 96, hydraulic pressure may be applied via hydraulic hose 81 through passageway 74 into groove 75 to slightly compress resilient bladder member 72 and resilient member 73 about and along wireline 60. Accordingly, annular resilient member 73 serves as a wireline wiper for wireline 60.
If blowout conditions are encountered in the well, well casing 96 is immediately sealed by sealing wireline seal assembly means 54 about and along wireline 60 to prevent the leakage of well fluids from the casing 96. This sealing is accomplished by the application of hydraulic pressure from hydraulic hose 81 through passageway 74 into groove 75, whereby bladder member 72 and annular resilient member 73 are strongly compressed against wireline 60, whereby well fluid leakage about and along wireline 60 is prevented.
After blowout conditions have occurred and the well is sealed by the above procedure, it is then necessary to remove the wireline suspended tool 97 from well casing 96. Preferably, the wireline suspended tool 97 is raised by pulling wireline 60 upwardly, so that wireline suspended tool 97 is disposed in a position adjacent cut-off valve 93, as shown in FIG. 4. It should be noted that as wireline 60 is raised, the leakage of well fluids from casing 96 is prevented by the compression of annular resilient member 73 about and along wireline 60 as wireline 60 passes upwardly through annular resilient member 73 of wireline seal assembly means 54.
When the wireline suspended tool 97 is in the approximate position shown in FIG. 4, the wireline 60 may be cut and clamped whereby the portion of the wireline 60 extending outwardly from wireline guide 99 may be easily handled. Of course, that portion of wireline 60 may be suitably clamped in a conventional manner so as to prevent wireline suspended tool 97 from falling downwardly into well casing 96. The portion of wireline 60 extending beyond wireline guide 99 is then passed through a second riser 100. As shown in FIG. 4, second riser 100 has a conventional stuffing box 101 disposed at its upper end 102. After wireline 60 is passed through second riser 100, it is passed through the conventional sealing means 103 of stuffing box 101.
Still referring to FIG. 4, the next step of the method of the invention is to attach the lower end 104 of the second riser 100 to the top of annular body 51. As shown in FIG. 4, the attachment of second riser 100 to annular body 51 is accomplished by engagement of the internal threads 105, formed in the interior lower surface of second riser 100, with the attachment means 57 associated with the upper end 52 of annular body 51. As seen in FIGS. 1 and 4, the second attachment means 57 associated with the annular body 51 comprises external threads 106 formed about the upper outer surface of annular body 51. Of course, it should be readily understood that any other suitable second attachment means 57 could be utilized in lieu of threads 106 on annular body 51 such as by providing a suitable flange connection.
After second riser 100 has been attached to the releasable annular wireline blowout preventer 50 of the present invention, as shown in FIG. 4, stuffing box 101 is actuated whereby stuffing box sealing means 103 is sealed about wireline 60. Then, valve 83 is opened, whereby the pressure difference between first riser 55 and second riser 100 is equalized. As shown in phantom in FIG. 4, a pressure hose 107 may be connected in any suitable manner between valve 83 and second riser 100 to allow the pressure equalization between first and second risers 55 and 100.
With regard to FIGS. 4 and 5, it should be noted that second riser 100 is shown in a break-away view, as at 108, whereby it should be understood that the length of second riser 100 is such that the combined length of the first and second risers is sufficient to enclose the wireline suspended tool.
After the pressure has been equalized between first and second risers 55 and 100, the wireline seal assembly means 54 is released from annular body 51 by operation of the releasing means 59. By rotation of the releasing means 59, or bolt heads 90, the end portions 87 of bolts 85 are moved outwardly from annular body 51 into the position shown in FIGS. 2 and 5, whereby wireline seal assembly means 54 is released from annular body 51.
Turning now to FIG. 5, it is seen that by raising wireline suspended tool 97, wireline cable head 98 will engage the guide receptacle 82 disposed on the lower portion of wireline sealing means 54. As wireline seal assembly means 54 is being raised outwardly from annular body 51 of the releasable annular wireline blowout preventer 50, leakage of well fluids is prevented by the sealing means 103 of stuffing box 101. As seen in FIG. 5 as the wireline suspended tool 97 is being raised, it in turn will raise the wireline seal assembly means 54 to the position shown in FIG. 5. Thus, the wireline suspended tool 97 and wireline seal assembly means 54 are disposed within the second riser 100, and the lower end of the wireline suspended tool 97 will clear and pass the cut-off valve 93. Because the second riser 100 must be long enough to accommodate the combined length of the wireline seal assembly means 54 and the major portion of the length of wireline suspended tool 97, it is readily apparent that the length of second riser 100 may be greater than the length of the first riser 55.
Still referring to FIG. 5, it is seen that after the lower portion of wireline tool 97 clears and passes the cut-off valve 93, the cut-off valve 93 may then be closed to seal the well. Piston members 94 and 95 move inwardly in a conventional manner to seal off the annular space within valve 93. After cut-off valve 93 is closed, the pressure within second riser 100 may be safely released and vented into the atmosphere. After the pressure has been released, the second riser 100, annular body 51, wireline suspended tool 97, and wireline seal assembly means 54 may be readily dismantled from one another until needed once again for conducting wireline operations.
The foregoing description of the invention has been directed in primary part to a particular preferred embodiment in accordance with the requirements of the Patent Statutes and for purposes of explanation and illustration. It will be apparent, however, to those skilled in this art that many modifications and changes in the method and apparatus of the present invention may be made without departing from the scope and spirit of the invention. For example, the annular body of the releasable wireline blowout preventer could be formed integrally with the first short riser, or the outer configuration of that body could be square with an internal annular construction.
It is applicant's intention in the following claims to cover such modifications and variations as fall within the true spirit and scope of the invention. | A method and apparatus for conducting wireline operations in oil and gas wells under blowout conditions is disclosed, wherein a releasable annular wireline blowout preventer is provided, whereby wireline operations may be conducted under normal operating conditions by only using a short riser and a releasable annular wireline blowout preventer. Under blowout conditions, a second riser may be attached to the releasable annular wireline blowout preventer to quickly enable a wireline suspended tool to be safely removed from the well, along with the releasable wireline seal assembly means of the blowout preventer. | 4 |
BACKGROUND OF THE INVENTION
The invention relates to a rotor for pressure sorters for sorting fibrous suspensions, such as those described and illustrated, for example, in U.S. Pat. Nos. 3,581,903, 3,849,302 and 4,155,841 or in EP No. 0 042 742-B1. Pressure sorters of this type have a rotationally symmetrical screen, mostly in the form of a screen cylinder, to which the fibrous suspension to be sorted is fed in the direction of the rotor axis, whereby the inner or outer side of the screen can form the inlet or inflow side of the screen. Mostly, the screen is arranged with a vertically oriented axis and the fibrous suspension to be sorted is supplied to the screen from above so that the upper end of the screen forms its inlet end. The rotor of this pressure sorter has a rotor axis coinciding with the screen axis and its operative regions rotate adjacent the inlet side of the screen. If the usable fibrous suspension flows through the screen from the inside to the outside, the rotor is arranged in the interior of the screen cylinder. If the inlet side of the screen is on the outside, the rotor has extending from its axis, a carrier which overlaps the screen wall and to which the regions of the rotor passing the outer side of the screen are attached. The invention does, however, also relate to those pressure sorters, in which the kinematic ratios are exactly the reverse, i.e. in which a screen rotating about its axis and a stationary "rotor" are provided.
The rotor of such a pressure sorter has the object of preventing the screen apertures from becoming clogged by fiber conglomerates or by impurities contained in the fibrous suspension. For this purpose, the rotor bears adjacent the screen inlet side cleaning elements which move through the fibrous suspension to be sorted and are designed such that they generate positive pressure surges in the fibrous suspension on their leading side and negative pressure surges on their rear side which, again, bring about flows flushing through and flushing back through the screen apertures. In some of the known pressure sorters according to the publications cited in the aforesaid, measures have been taken in addition to generate turbulences in the fibrous suspension to be sorted at the screen inlet side. These turbulences are intended to prevent the formation of a fibrous fleece in the fibrous suspension to be sorted at the inlet side of the screen. For this purpose, the known cited pressure sorters are provided at the screen inlet side with strips placed on the screen or grooves worked into the screen which extend parallel to the rotor axis, or recesses are worked into the screen wall at the screen inlet side in the region of the screen apertures. This unevenness at the screen inlet side generates the desired turbulences in the fibrous suspension to be sorted since the fibrous suspension to be sorted flows helically along at the screen inlet side as a result of the rotating rotor. These turbulences counteract the formation of any fibrous fleece and they also have the effect that the circulating fibrous suspension which has been thickened to a great extent at the screen inlet side due to fractionation is broken up such that a larger portion of the usable fibers can pass through the screen apertures. Screens having strips placed thereon or grooves worked therein are, however, subject to quite considerable great wear and tear, above all during sorting of fibrous suspensions recovered from mixed waste paper or the like which contain a considerable proportion of solid impurities which lead to rapid wear and tear on the edges of the strips and grooves. Moreover, these screens are expensive to manufacture. This also applies for screens, in which recesses are worked into the screen wall in the region of the screen apertures from the side of the screen inlet.
It is obvious that these comments also apply for those pressure sorters in which the screen is caused to rotate and the cleaning elements are stationary.
The rotors of the known pressure sorters have either a set of arms attached to a central rotor shaft and strip-like cleaning vanes as cleaning elements, which are attached to the outer ends of these arms, or the rotor has a circular-cylindrical casing with cleaning elements attached to the side facing the screen, these cleaning elements having, like the strip-like cleaning vanes mentioned above, a profile which is in cross section transverse to the rotor axis similar to an airfoil. In the latter case, the cleaning elements can also be strip-like cleaning vanes. However, rotors having a circular-cylindrical casing are also known, to which short vane pieces are attached as cleaning elements to avoid pulsations in the fibrous suspension containing usable fibers, the so-called accepted material, leaving the pressure sorter.
SUMMARY OF THE INVENTION
The present invention relates to a novel cleaning vane for pressure sorters of this type and the object underlying the invention was to provide cleaning vanes, with which a high throughput capacity can be achieved for a pressure sorter without having to use a screen which is expensive to produce and susceptible to wear and tear. The throughput capacity is to be understood as that amount of fibrous suspension which passes through the screen apertures per unit of time and per unit of area of the screen.
In a rotor for pressure sorters for sorting fibrous suspensions, which has a plurality of cleaning vanes provided for rotation along the inlet side of the pressure sorter screen and extending transversely to the direction of isolation and approximately parallel to the screen inlet side, these vanes having in cross section transverse to the rotor axis a profile similar to an airfoil, the object of the invention may be accomplished in that at least some of the cleaning vanes have at least regions (return regions) having a profile at the leading side designed as an approximately acute angle--pointing in the direction of rotation towards the screen inlet side--with a first side facing the screen and a second side facing away from the screen for urging the fibrous suspension away from the screen, the second side forming an obtuse angle with the direction of circulation and the first side extending approximately parallel to the direction of rotation or forming herewith an acute angle opening opposite to the direction of rotation. An inventively designed rotor may have self-supporting, strip-like cleaning vanes, of which all or some are designed according to the invention. An inventive cleaning vane can be provided throughout or only in sections with an inventively designed return region. A rotor constructed according to the invention can, however, also have a rotationally symmetrical casing, the side of which facing the screen is provided with inventive cleaning vanes for which the same applies as for the self-supporting cleaning vanes described above and designed according to the invention. Short vane pieces can also be placed on the rotor casing and all or some of these be designed according to the invention.
An inventively designed return region of a cleaning vane causes the ring of fibrous suspension (which is formed at the screen inlet side due to fractionation, circulates at a lower speed than the rotor and has a higher substance density) to be moved away from the screen so that it mixes at a radial distance from the screen with fibrous suspension having a lower substance density before this part of the fibrous suspension again reaches the screen. With correspondingly constructed, inventive cleaning vanes it is possible not only to generate the positive and negative pressure surges in the fibrous suspension to be sorted, which cause the screen apertures to be flushed and reflushed, but also to prevent fiber conglomerates, in particular the formation of a fibrous fleece or mat at the inlet side of the screen due to the inventively designed return regions because the thickened portion of the fibrous suspension to be sorted which forms in front of the screen inlet side is always being urged away from the screen, thinned by mixing with fresh fibrous suspension and then conveyed back to the screen. When using an inventive rotor it is not, therefore, necessary to use a screen with an inlet side which is provided with strips, grooves or other recesses and so the problems of cost and wear and tear connected with such screens can be avoided.
The portions of fibrous suspension urged away from the screen inlet side by the inventive return regions can be fed back to the screen inlet side due to the pressure gradient between the inlet of the pressure sorter for the fibrous suspension to be sorted and the outlet of the pressure sorter. However, in an advantageous development of the inventive rotor, some of the cleaning vanes have at least regions (supply regions) arranged relative to the return regions such that the fibrous, suspension urged away from the screen by the return regions impinges on these supply regions which have, in cross section transverse to the rotor axis, on their leading side a first side facing the screen and forming an acute angle with the direction of circulation. Whereas at the leading side of the return region shape of the first side prevents the fibrous suspension portions adjacent the screen inlet side from being urged against the screen by the return regions, and these fibrous suspension portions are, rather, urged away from the screen inlet side by the second side of the return regions, the first side of the supply regions has the effect that the fibrous suspension portions previously urged away from the screen inlet side are, after being mixed with fresh fibrous suspension, returned to the screen inlet side when the cleaning vanes pass through the fibrous suspension to be sorted since the sides of the supply regions, which face the screen and are located on the leading side of these supply regions, form with the screen an intake gap for the fibrous suspension which tapers opposite to the direction of circulation.
If an inventive rotor has self-supporting cleaning vanes or strip-like cleaning vanes placed on a rotor casing, some of these cleaning vanes can be designed throughout or in sections such that the inventive supply regions are formed hereby. It would, therefore, be possible in the case of, for example, strip-like cleaning vanes to construct successive cleaning vanes in the direction of circulation alternatingly as return regions and supply regions, and over the entire length of the relevant cleaning vane. In the case of a rotor having a rotationally symmetrical casing and relatively short vane pieces placed thereon, a certain number of vane pieces will be constructed as return regions and others as supply regions although it would, of course, also be conceivable to construct a vane piece as return region over part of its length and as supply region over another part of its length.
As already mentioned, in the pressure sorters in question the fibrous suspension to be sorted is fed to the rotationally symmetrical screen from one end thereof so that the suspension flows helically along the screen inlet side from the inflow end of the screen to its other end as a result of relative rotation between screen and rotor. In order to transport that part of the fibrous suspension to be sorted which cannot pass through the screen apertures, namely the so-called rejected material, more quickly to the discharge end of the screen in the direction towards the rejected material outlet of the pressure sorter, it is already known for the cleaning vanes of a rotor--when seen in the direction of the rotor axis from the inlet end of the screen to the other screen end--to form with the rotor axis such an acute angle that the ends of the cleaning vanes facing the inlet end of the screen lead their other ends in the direction of rotor circulation. This measure is also recommended for the inventive rotor. A second advantage is then achieved, namely that that part of the fibrous suspension urged away from the screen by the return regions reaches the supply regions of the cleaning vanes and is thus fed back to the screen inlet side in a thinned or loosened form. It is obvious from the above that reference can also be made to the inlet end of the rotor instead of to the inlet end of the screen.
In order to ensure that fibrous suspension urged away from the screen by the return regions does not again impinge on return regions of the rotor, it is recommended in addition that the rotor be designed such that successive return regions in the direction of circulation are arranged to be offset relative to one another in the direction of the rotor axis. In the case of a rotor also having supply regions it is, consequently, also of advantage for the successive supply regions in the direction of circulation to be arranged to be offset relative to one another in the direction of the rotor axis. If, in this case, as in a preferred embodiment of the inventive rotor, return regions and supply regions are arranged relative to one another such that--when seen in the direction of circulation--return regions and supply regions alternatingly follow one another, the helical flow of the fibrous suspension to be sorted along the screen inlet side results in the suspension, which has been urged away from the screen inlet side by a return region, first impinging on a supply region, particularly when the length of the return regions and the supply regions measured in the direction of the rotor axis is identical and the amount by which these regions are offset is equal to this length.
Advantageously, the first side of the return regions facing the screen extends approximately parallel to the direction of circulation although this side can also form with the direction of circulation an acute angle opening towards the rear. The first embodiment mentioned is more advantageous because this first side does not then cause any drop in pressure in the fibrous suspension adjacent the screen inlet side immediately behind the leading edge of a return region; this drop in pressure would counteract the urging away of the fibrous suspension from the screen inlet side by the second profile side of the return region.
In order to feed that part of the fibrous suspension urged away from the screen inlet side by a return region as completely as possible to a supply region (due to the helical flow path of the fibrous suspension or the inclination of the cleaning vanes relative to the rotor axis), a rotor is recommended which has an outer surface facing the screen and designed to be rotationally symmetrical, the cleaning vanes being placed thereon, whereby the approximately acute-angled profile portion of the return regions is radially spaced from the rotor outer surface such that the return region, together with its acute-angled profile portion and the rotor outer surface, forms a channel extending transversely to the direction of circulation. When, as in other parts of the specification and the claims, an extension transversely to the direction of circulation is specified, this is not intended to be understood only as an angle of 90° since this angle may deviate more or less from a right angle according to the inclination of the cleaning vanes relative to the rotor axis and the pitch of the helical flow path of the fibrous suspension to be sorted.
The inventive measures have a particularly advantageous effect when the portions of the fibrous suspension to be sorted which are urged away from the screen by the return regions are fed back again to the screen inlet side under the influence of centrifugal forces, i.e. when the inventive rotor is provided adjacent the inner side of the screen for circulation. This means that in preferred embodiments of the inventive rotor the first sides of the cleaning vanes are located on the outer side of the rotor.
In order to achieve a practicable flushing back effect for the screen apertures with the inventive cleaning vanes, as well, an inventive embodiment is recommended in which the profile of the cleaning vanes has, downstream of the first side in the direction of circulation, a third side facing the screen and forming with the direction of circulation an acute angle opening towards the rear.
With regard to the flow components of the fibrous suspension to be sorted which are directed from the inlet end to the outlet end of the screen or rotor, it is advantageous for the return regions to have adjacent the first side in the direction of the rotor axis an inclined side surface facing the inlet end of the screen or rotor and forming an impinging surface for a flow directed from the inlet end in the direction of the rotor axis, this surface sloping upwards in the direction towards the screen.
As already mentioned, rotors which have offset, short vane pieces are recommended for breast box installations for avoiding pulsations in the breast box. For material treatment installations and for fibrous suspensions having a high substance density inventive rotors are recommended in which at least some of the cleaning vanes, preferably all the cleaning vanes, are designed as strips extending transversely to the direction of circulation and approximately parallel to the screen inlet side, return and supply regions alternatingly succeeding one another along said strips. This enables particularly intensive turbulences to be generated in the fibrous suspension to be sorted.
In the case of rotors of this type having strip-like cleaning vanes it is advantageous for the strips--when seen in the direction of the rotor axis--to form an angle of between approximately 5° and approximately 45° with the rotor axis. Since the substance density of the fibrous suspension to be sorted increases as its passes from the inlet end to the outlet end of the screen and it is of advantage for that part of the fibrous suspension, in which impurities have accumulated, to be conveyed relatively quickly to the outlet end of the screen, in a preferred embodiment of a rotor provided with strip-like cleaning vanes the strips form over a greater portion of their length, which faces the inlet end of the screen and preferably amounts to approximately 2/3 of the length of the cleaning vanes, a smaller lead angle relative to line parallel to the rotor axis than the remaining, shorter portion of these strips. Expressed the other way around, this means that the shorter portions of the strips facing the outlet end of the screen form a larger lead rotation to line parallel to angle the rotor axis.
BRIEF DESCRIPTION OF THE DRAWINGS
Additional features, advantages and details of the invention result from the following description and the attached drawings of two particularly preferred embodiments of the inventive rotor or rather of pressure sorters comprising an inventive rotor. In the drawings,
FIG. 1 shows a first pressure sorter comprising a first embodiment of the inventive rotor, in a vertical section through the rotor axis;
FIG. 2 shows a section along line 2--2 in FIG. 1 through a section of the screen of the pressure sorter and the rotor;
FIG. 3 shows a section along line 3--3 in FIG. 2;
FIG. 4 shows a section along line 4--4 in FIG. 2;
FIG. 5 shows a sectional illustration corresponding to FIG. 1 through a second pressure sorter comprising a second embodiment of the inventive rotor;
FIG. 6 shows a section corresponding to FIG. 2 along line 6--6 in FIG. 5 through part of the screen and the rotor;
FIG. 7 is a view of the rotor part shown in FIG. 6, seen in the direction of arrow "A" in FIG. 6, with the screen indicated by dash-dot lines;
FIG. 8 is a perspective view of the upper portion of the vane 50 generally as shown in FIG. 1 on the left of the rotor 32;
FIG. 9 shows a perspective view of the upper portion of the vane shown in FIG. 1 in front of the axis 20 of the rotor, and
FIG. 10 is a sectional view of a portion of the upper right corner area of the rotor 32 as shown in FIG. 1 with a front view of one of the vanes, generally along line 10--10 of FIG. 1.
DETAILED DESCRIPTION OF THE INVENTION
The pressure sorter 10 illustrated in FIG. 1 has a housing 12 comprising an inlet pipe 14 for the fibrous suspension to be sorted, an outlet pipe 16 for the so-called accepted material, i.e. that part of the fibrous suspension which has passed through the screen of the pressure sorter and contains the usable fibers, as well as an outlet pipe 18 for the so-called rejected material, namely that part of the fibrous suspension which is held back by the screen of the pressure sorter and contains the impurities as well as fiber conglomerates. Two circular partition walls 22 and 24 which bear a screen cylinder 26 are secured in the housing 12 which, with the exception of the pipes 14, 16 and 18, is designed to be rotationally symmetrical, in particular circular cylindrical, relative to an axis 20. The screen cylinder has a plurality of screen apertures 28 and forms with the housing 12 an outer annular chamber 30, the so-called accepted material chamber, between the partition walls 22 and 24. A rotor 32 is arranged within the screen cylinder 26. This rotor has, in the illustrated embodiment, a closed, circular- cylindrical rotor casing 34 and its axis, like the axis of the screen cylinder 26, coincides with the axis 20 of the housing 12. A housing base 36 is secured in the housing 12 beneath the rejected material outlet pipe 18. This base mounts a bearing 38 for a rotor shaft 40, to which the rotor 32 is secured in a manner not illustrated and which can be drive by means of a belt pulley 42 secured to the rotor shaft. The direction of rotation or circulation of the rotor 32 is indicated in FIG. 1 by the arrow R. Since the external diameter of the rotor casing 34 is somewhat smaller than the internal diameter of the screen cylinder 26, these two elements of the pressure sorter 10 form an inner annular chamber 46, in which the fibrous suspension to be sorted flows helically from top to bottom. The part of the fibrous suspension retained by the screen cylinder 26 passes into the rejected material chamber 48 beneath the rotor 32 and above the housing base 36, into which the rejected material outlet pipe 18 opens.
On the outside of the rotor casing 34, a plurality of strip-like cleaning vanes 50 are secured at equal distances from one another in the direction of circulation R. When seen in the side view vertically to the axis 20, these vanes form with this axis an acute angle δ which is preferably between approximately 5° and approximately 45° and may vary along the rotor casing 34 from top to bottom, i.e. the cleaning vanes 50 need not have the shape of straight strips. As clearly shown in FIG. 1, the cleaning vanes 50 form alternatingly successive return regions 52 and supply regions 54 in the longitudinal direction of the strip and these regions will be described in more detail in the following.
The fibrous suspension to be sorted in the pressure sorter 10 is fed into the inlet pipe 14 under pressure and, as the rotor is closed at the top, flows from above into the inner annular chamber of the pressure sorter 10. Due to rotation of the rotor 32, the fibrous suspension to be sorted flows helically through the inner annular chamber 46 from top to bottom. The part of the fibrous suspension containing the individual, usable fibers passes through the screen apertures 28 into the accepted material chamber 30 and leaves the pressure sorter 10 via the accepted material outlet pipe 16. The part of the fibrous suspension retained by the screen cylinder 26, namely the rejected material, leaves the pressure sorter via the rejected material chamber 48 and the rejected material outlet pipe 18.
The inventive construction of the cleaning vanes 50 will now be explained in greater detail on the basis of FIGS. 2 to 4, 8, 9 and 10.
Each of the return regions 52 has at the front in the direction of circulation R an acute-angled profile portion 52a having a first side 52b facing the screen cylinder 26 and a second side 52c facing away from the screen cylinder. The first side 52b extends approximately parallel to the screen cylinder 26 or to the direction of circulation R, whereby it is possible, however, to have a small acute angle between the first side 52b and the direction of circulation R which opens to the rear. The second side 52c forms an obtuse angle α with the direction of circulation R and merges in the direction towards the rotor axis 34 into a wall 52e which, in cross section vertical to the rotor axis 20, extends approximately radially so that each return region 52 with its second side 52c and its radially extending wall forms with the rotor casing 34 a channel 56 extending approximately transverse to the direction of circulation R.
Each of the supply regions 54 has at the front in the direction of circulation R a first side 54b which, in cross section normal to the rotor axis 20, forms with the direction of circulation R an acute angle β opening towards the front.
On their rear sides the return regions 52 and the supply regions 54 have third sides 52d and 54d, respectively, which are aligned with one another and form with the direction of circulation R an acute angle γ opening towards the rear.
For the sake of simplicity, only a few screen apertures 28 have been depicted in FIG. 2. However, it goes without saying that the screen cylinder 26 is provided overall with this type of screen aperture. For the sake of completeness, the inlet side of the screen cylinder 26 has been designated in FIG. 2 as 26a, i.e. the accepted material passes through the screen apertures 28 in radial direction from the inside to the outside.
The revolving rotor 32 with its cleaning vanes 50 has the effect that these vanes generate positive and negative pressure surges in the fibrous suspension to be sorted; positive pressure surges result in the fibrous suspension upstream of the cleaning vanes 50 in the direction of circulation R and negative pressure surges in the region of the third sides 52d and 54d, respectively. The positive pressure surges occurring upstream of the cleaning vanes force an increased throughput through the screen apertures 28 whereas the negative pressure surges occurring in the region of the inclined sides 52d and 54d, respectively, have a flushing back effect at the screen apertures 28. Due to the acute-angled profile parts 52a of the return regions 52 which revolve at a very small distance from the inlet side 26a of the screen cylinder 26, that part of the fibrous suspension immediately adjacent the screen inlet side 26a is urged or diverted away from the screen cylinder 26, thanks to the second sides 52c of the return regions 52 which are inclined rearwards and radially inwards. The suspension portions thickened due to the effect of the screen apertures 28 are therefore conveyed radially inwards into regions in which the fibrous suspension to be sorted has a lower substance density. Due to the inclination of the cleaning vanes 50 relative to the rotor axis 20 through an angle β, as illustrated in FIG. 1, the thickened fibrous suspension is conveyed in the channels 56 along the relevant cleaning vane, according to FIG. 1 downwards, to the relevant adjacent supply region 54 and again fed to the screen inlet side 26a by the first side 54b of the supply region. Since the first side 54b is inclined through an angle β, this portion of the fibrous suspension which is diverted towards the screen inlet side meets portions of the fibrous suspension flowing in the direction of circulation R in the vicinity of the screen cylinder 26 as a result of the revolving cleaning vanes 50. This results not only in a mixing of those fibrous suspension portions circulating in direction R in the vicinity of the screen inlet side 26a with the fibrous suspension portions diverted along the inlet side 26a but also in relatively strong turbulences due to the almost oppositely directed flows and these turbulences prevent the formation of a fibrous fleece in the vicinity of the screen inlet side 26a.
The inventive construction of the cleaning vanes 50 therefore leads to flushing and flushing back pulses at the screen apertures 28, it counteracts the formation of thickened fibrous suspension portions in the vicinity of the screen inlet side 26a and, finally, it causes turbulences in the region of the screen inlet side 26a which counteract the formation of a fibrous fleece.
As already mentioned, the fibrous suspension to be sorted flows helically through the inner annular chamber 46 from top to bottom and, consequently, has a flow component directed downwards, which is not intended to counteract the rotor with its cleaning vanes 50. For this reason, the return regions 52 are, finally, provided at the top (cf. FIGS. 3 and 4) with inclined side faces 50d which resist the flow component of the fibrous suspension in the inner annular chamber 46, which is directed from top to bottom, to a lesser degree than if the return regions 52 of the cleaning vanes 50 were provided on both sides with side faces which extend approximately normal to the rotor axis 20, as is the case with the lower side faces 50e.
The strips 50 may be formed of any suitable material by any appropriate forming and shaping technique. In one example the strips 50 may be made from stainless steel and their overall outer profile obtained by drawing a bar of the stainless steel through an appropriate die. The strips may then be machine to provide the areas of reduced cross section and respective surfaces, such as surfaces 54b, 50d and 54f.
As already mentioned, the cleaning vanes, 50 need not have, overall, the same inclination δ relative to the rotor axis 20, as shown in the case of the cleaning vanes illustrated in FIG. 1. In an inventive modification which has not been shown in the drawings the lower third of the cleaning vanes 50 is inclined to a greater extent relative to the rotor axis 20 than the upper two thirds of the cleaning vanes 50, i.e. the strip-like cleaning vanes are, in this variation, bent. In this way, a stronger, downwardly directed conveying effect of the cleaning vanes will result in the lower third of the rotor and this causes the rejected material in the lower third of the screen cylinder 26, which is already thickened to a considerable degree, to be more rapidly urged away into the rejected material chamber 48.
In a further variation of the pressure sorter according to FIGS. 1 to 4, which is not illustrated in the drawings, the cleaning vanes 50 are broken up into individual, short vane pieces corresponding to the return regions 52 and the supply regions 54 and these vane pieces are distributed more or less equally around the circumference of the rotor casing 34. In this embodiment, the return regions 52 would be arranged at the same places on the rotor casing as the return regions 54 of the strip-like cleaning vanes 50, and the supply regions 52 would be arranged between the cleaning vanes 50 in the direction of circulation R.
In all these variations, and also in the embodiment illustrated in FIGS. 1 to 4, the return regions 52, on the one hand, and the supply regions 54, on the other, of successive cleaning vanes in the direction of circulation R are, as clearly shown in FIG. 1, offset relative to one another in the direction of the rotor axis 20 by the width of a region, i.e. in the direction of circulation R a return region 52 is followed by a supply region 54.
In the embodiment illustrated in FIGS. 5 to 7, the rotor is designed as an open structure, i.e. it has no rotor casing, and the cleaning vanes are connected with the rotor shaft via radially extending supporting arms. Otherwise, the pressure sorter of FIGS. 5 to 7 is designed in the same manner as the pressure sorter of FIGS. 1 to 4 and so the same reference numerals as those according to FIGS. 1 to 4 have been used for corresponding parts, with an apostrophe added. It should therefore also be sufficient to merely explain in the following the design of the rotor of the pressure sorter according to FIGS. 5 to 7.
The rotor 32' of the pressure sorter 10' shown in FIGS. 5 to 7 has arms 34' attached to the rotor shaft 40' in a star formation, i.e. they extend radially, and a cleaning vane 50' is secured to each of these arms. These cleaning vanes are again of a strip-like design and return regions 52' and supply regions 54' follow each other alternatingly along each of these cleaning vanes. As is particularly apparent from FIG. 6, the return regions 52' again have a profile part 52a' which forms an acute angle in cross section and has a first side 52b' extending approximately parallel to the direction of circulation R and a second side 52c' forming an obtuse angle α with the direction of circulation R. The adjacent supply regions 54' have on their inflow side a first side 54b' facing the screen inlet side 26a and forming an acute angle 62 with the direction of circulation R. The backs of the return regions 52' and the supply regions 54' are formed by third sides 52d' and 54d', respectively, which form with the direction of circulation R an acute angle γ opening to the rear.
In this embodiment, as well, the fibrous suspension portions adjacent the screen inlet side 26a are urged away from the screen inlet side inwards in radial direction by the second sides 52c' of the return regions 52 and after mixing with fibrous suspension portions having a lower substance density diverted by the first sides 54b' of the supply regions 54' back towards the screen inlet side 26a so that the desired turbulence result. With the exception of the function of channels 56 of the embodiment according to FIGS. 1 to 4, the cleaning vanes 50' result in the same effects as the cleaning vanes 50. | Rotor for pressure sorters for sorting fibrous suspensions, comprising a plurality of cleaning vanes provided for the circulation on the inlet side of a screen cylinder of the pressure sorter, these vanes being designed in sections as return regions and in sections as supply regions; the return regions are designed such that they urge the fibrous suspension portions adjacent the screen inlet side away from the screen cylinder, whereupon these fibrous suspension portions are diverted by the supply regions of the cleaning vanes towards the screen inlet side and fed back to the latter. | 3 |
BACKGROUND OF THE INVENTION
This invention relates to an embroidery machine. More particularly, this invention relates to an embroidery machine which makes it possible to produce embroidery designs automatically on a suitable woven support.
It is well known that embroidery work is usually very intricate and has to be carried out by specialists. Consequently, attempts have been made to automate the embroidery work by adopting digitization techniques known in other fields of activity. However, the digitization of embroidered designs having highly diverse forms, with several thread colors and with variable thread concentrations, is very costly and requires the use of complicated equipment involving a high capital outlay. Moreover, if it is desired to be able to modify the castoff of the needle or needles, and the orientation of the thread in the embroidered design, automation by the technique described above becomes practically impossible with the technical means available at the present time.
The object of the present invention is to provide a new embroidery machine which makes it possible to produce embroidery designs automatically in accordance with a design stored in a memory, taking into account all of the parameters which apply when manual embroidery is carried out.
Another object of the present invention is to provide a very fast embroidery machine which makes it possible to execute, at a variable speed, the following relative needle/fabric movements: movements in the X and Y axes, angular rotation and needle cast-off.
Yet another object of the present invention is to provide an embroidery machine which automatically executes the embroidery designs stored on a storage medium by electronic and mechanical means; and which records the movements of an embroidery specialist who executes, as a model, the embroidery design to be produced automatically by the machine.
SUMMARY OF THE INVENTION
The present invention provides an automatic embroidery machine which uses the programming technique well known in the construction of robots operating by the "teach-by-example" method (recording during execution).
In accordance with the present invention, an embroidery machine of the type mentioned above, includes on its stand, at least one needle support associated with the drives for the vertical to-and-fro and cast-off movements, and a tension frame intended for the fabric to be embroidered and mounted so as to be rotatable about its central axis and displaceable in two perpendicular directions in the same plane at right angles to the central axis. The frame is equipped with means for reading the angular position, means for reading the positions in the X and Y directions, associated drives in the X and Y directions, and a rotary drive. The reading means is connected to an electronic processing unit which permits the storage of the information received during manual work; and which allows control of the above-mentioned drives in accordance with the stored information during automatic work.
In order to make it easier for the tension frame of the fabric to be embroidered to execute manual movements which are impeded by the friction of the drive mechanisms, the frame is mounted in a second frame via stress-sensitive probes which detect the forces exerted in the X and Y directions and which thus actuate the corresponding drives. This arrangement permits manual work which is assisted and which consequently becomes much easier. Advantageously, the various positions to be stored in the processing unit are read in the drives as a result of a special arrangement thereof which is known per se.
In accordance with a preferred embodiment of the present invention, the processing unit permits processing to be carried out in five axes, that is, in the X and Y directions, rotary movements, variable needle cast-off and the speed of the main drive motor for the movements of the needle head. Advantageously, the needle head has two or, preferably, three needles, thus making it possible to speed up both manual and automatic work.
The above-discussed and other features and advantages of the present invention will be apparent to and understood by those skilled in the art from the following detailed description and drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
Referring now to the drawings, wherein like elements are numbered alike in the several FIGURES:
FIG. 1 is a front elevation view of the embroidery machine of the present invention;
FIG. 2 is a partial plan view of the arrangement of the fabric tension frame of the present invention;
FIG. 3 is a schematic block diagram of the regulation loop of the drive motors used in the present invention; and
FIG. 4 is a schematic block diagram of the electronic control showing the various functions in the processing unit of the present invention.
DESCRIPTION OF THE PREFERRED EMBODIMENT
With reference to FIG. 1, the embroidery machine of the present invention is comprised of a table 1 mounted on a table stand (known per se), a needle support 2 associated with drives 3 for the to-and-fro and cast-off movements of these needles, a movable tension frame 5 for the fabric to be embroidered, position reading means and drive means and an electronic processing unit 7.
The purpose of the embroidery machine in accordance with the present invention is to permit the recording of an embroidered design executed by a specialist, such that it can be repeated automatically as required. Furthermore, the manual movements of the fabric tension frame, which are impeded by mechanical friction, etc., are advantageously assisted in order to make the job easier for a specialized operator executing the embroidery design to be copied.
For this purpose (FIG. 2), the fabric tension frame 5 which is comprised of two rings 50 and 51, between which the fabric to be embroidered is stretched, is arranged in an annular frame 52 mounted so as to be rotatable about its central axis in movable frames 53 and 54 which are displaceable on table 1 in the X and Y directions. Mounted between the two frames 53 and 54 of movable frame 5 are stress-sensitive probes which, for example, take the form of annular elements 41 and 42 equipped with elements sensitive to the deformations of, for example, piezoelectric materials, or strain gages, and which make it possible to detect the operator's intention to shift the tension frame in a linear movement in the perpendicular X and Y directions. As a result, when the specialized operator exerts a force on fabric tension frame 5, the information detected is transmitted to the drive motors (not shown) of movable frame 53 and 54.
The rotary movements of the motors are transmitted to the annular frame 52 in a known way, for example, by means of non-slip rollers. Thus, the operator's movements are assisted and, because of the use of special motors (which are known), the various movements are also recorded and processed in processing unit 7 in order to be stored on, for example, a magnetic medium. FIG. 2 also shows the angular position reading device 43 (known per se) and electronic interface and preamplification circuits 45 and 46.
The other controls, such as the setting 9 of the speed of the main motor 11 driving the needles; and the setting 13 of the needle cast-off are similarly recorded in processing unit 7.
Processing unit 7 contains the electronic circuits necessary for regulating the drive motors, an information storage unit, such as, for example, a floppy-disk unit 71, and an operator communication unit, such as a keyboard 72 and a screen 73. Preferably, electronic processing unit 7 includes text processing functions which make it possible to compose, on the screen, fractions of an embroidered design which are executed by a specialized operator and recorded on floppy disks. It is thus possible to build up, on floppy disk, a "library" of embroidered designs which can be called up and composed so as to be executed automatically by the machine. The electronic processing unit 7 can also include functions which make it possible to modify the designs electronically, such as a modification of dimensions, deformation of the designs by the action of speed and other such variables.
Preferably, the rotational speed of main motor 11 is synchronized with the other movements. Also, the drive motors are regulated in accordance with the diagram shown in FIG. 3.
In a preferred embodiment of the present invention, the electronic processing unit 7 (FIG. 4) comprises two central or functional units, one unit being intended for receiving the information from the motors and for controlling the same, and the other unit intended for actual processing, such as storage, the text processing functions and the communication functions (for example by means of a keyboard and a screen). Preferably, the two functional units are controlled by a single microprocessor.
It will be appreciated that FIGS. 3 and 4 will be easily understood by a person of ordinary skill in the art; and that electronic processing unit 7 as described in FIG. 4 and the regulation of the drive motors as described in FIG. 3 could be made and used by said person of ordinary skill in the art from a review of the foregoing specification and drawings.
While preferred embodiments have been shown and described, various modifications and substitutions may be made thereto without departing from the spirit and scope of the invention. Accordingly, it is to be understood that the present invention has been described by way of illustrations and not limitation. | An embroidery machine is presented which automatically executes the embroidery designs stored on a storage medium by electronic and mechanical means; and which records the movements of an embroidery specialist, who executes as a model, the embroidery design to be produced automatically by the machine. | 3 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to drilling or boring apparatus and more particularly to means for drilling or boring holes downwardly into the earth.
2. Description of the Prior Art
This invention provides particular advantages when employed in mobile self-propelled drilling apparatus that may be moved from one location to another to drill holes in the earth at different locations as for drilling blast holes; the invention therefore will be described in connection with such apparatus.
Heretofore, drilling apparatus of this type has often comprised a mobile vehicle body having power means for propelling the apparatus, and at one end a drilling mast adapted to be raised to an upright position to permit drilling and to be lowered to a generally horizontal position to facilitate travel of the vehicle from one location to another. The mast has had associated with it means for storing drill rods and placing them into a location where they could be incorporated into a drill string and for removing the drill rods from the drill string and storing them.
In most apparatus of this type, the drill rods are quite heavy, each often weighing several hundred pounds and being 12 to 20 feet long or even longer. The size and weight of these drill rods have prevented handling of the rods manually. Therefore, it is desirable that mechanical means be provided to put stored drill rods into proper position to be connected in the drill string for drilling purposes, and after drilling is finished to disconnect the drill rods from the drill string and store them in drill storage means on the apparatus. Moreover, it is very desirable that this operation be performed rapidly in order to reduce costs of labor, fuel, and to obtain a high rate of usage of the apparatus which usually is quite expensive. It is also important that the handling of the drill rods and the drilling operation be performed with a maximum of safety to operators.
Heretofore, various types of mechanical means have been provided or proposed for handling and storing the drill rods but in general such means has not been as effective as desired, for various reasons.
Prior drilling apparatus, and particularly the means for handling and storing the drill rods have often been excessively complicated and liable to costly break-downs, particularly under the severe conditions of use in the field in which the apparatus is subjected to substantial forces and to dust and abrasion. Prior apparatus often has not been as dependable for these and other reasons, and hence has resulted in added costs of drilling. Often prior apparatus has not operated sufficiently automatically to accurately place the drill rods for inclusion in the drill string, and when the drill rods are removed to place them in storage; often such prior apparatus has required considerable manipulation and control by the operator. These problems have been intensified because of the large inertial forces involved in starting and halting movement of groups of heavy drill rods in the handling and storage means.
SUMMARY OF THE INVENTION
It is an object of the invention to provide drilling apparatus that satisfies all or as many as desired of the above features of satisfactory and economical drilling, and that overcomes all or as many as desired of the above disadvantages.
In one aspect, the apparatus of the invention comprises mobile drilling apparatus having a vehicle body carrying power means for propelling the apparatus and for driving the drilling equipment, and having a drilling mast adapted to be raised to an upright vertical position and to be lowered to a generally horizontal position for traveling, the power means on the vehicle body including power train means adapted to provide power to propel the apparatus from one location to another, to provide power for rotating and moving vertically a drill head which drives the drill string for drilling, and to provide power for auxiliary equipment such as to provide air under pressure to pass through the drill string and into the drilled hole to remove dust and debris.
In another aspect, the apparatus provides a unique and effective mechanical means for supplying power to the drilling head for rotating the drill string, which means includes disconnect means which can automatically establish as the mast is moved to its upright position a driving connection between the power means on the vehicle body and means on the mast for supplying power to the drilling head, and which can automatically disconnect such power means when the mast is moved to its horizontal position.
Another aspect of the invention provides improved drill rod storage and handling means that is mounted on the mast, and embodies a rotatable storage rack that is mounted on the mast and a geneva wheel mechanism operating between the mast and the rack that accurately and precisely rotates the storage rack to a position where each of a plurality of drill rods carried by the storage rack can be sequentially located with its axis along the drilling axis and that makes possible the automatic sequential connections of such drill rods to a drilling head on the mast and to lower elements such as lower drill rods and also makes possible ready automatic sequential removal of drill rods from the drill string and placing of the rods in the storage rack.
The invention also provides improved means for holding a drill rod against rotation while another element such as the drilling head that is connected to the rod by a threaded joint is rotated to disconnect the joint, and also means for turning a drill rod about its axis sufficiently to loosen a threaded joint between the drill rod and another element such as another drill rod.
The invention also provides an improved drill rod, which may be advantageously used in apparatus of the type described above, which embodies configurations making it readily possible to remove the drill rod from a storage rack and place it in a drill string, to remove the rod from the string and store it, to hold the rod against rotation for disconnecting purposes, and to permit the rod to be turned to loosen a threaded connection by which it is connected to another element, disconnect the drill rod from the drilling head and from elements below the drill rod such as lower drill rods or cutting head.
BRIEF DESCRIPTION OF THE DRAWINGS
These and other objects, features and advantages of the invention will become apparent from the following description of a preferred apparatus and preferred drill rod embodying the invention, in connection with the following drawings in which:
FIG. 1 is a side elevation of illustrative mobile drilling apparatus of the invention, the mast being shown in its upright position and the stabilizing jacks shown as extended and contacting the earth to stabilize the apparatus for drilling;
FIG. 2 is a view from the right-hand end of the apparatus of FIG. 1, to the same scale;
FIG. 3 is a vertical sectional view of the apparatus of FIG. 1 but to a slightly larger scale;
FIG. 4 is a view from the right-hand end of the apparatus of FIG. 3, to the same scale;
FIG. 5 is a plan of the apparatus of FIG. 1, to the scale of FIG. 3;
FIG. 6 is a view of the apparatus of FIG. 1, to the scale of FIGS. 2 and 3, showing the mast and the drill rod storage and handling rack generally horizontal for traveling;
FIG. 7 is a side view to a larger scale showing means for driving various portions of the apparatus;
FIG. 8 is a section to a still larger scale of a power divider gear box included in the driving means;
FIG. 9 is a plan to a still larger scale showing braking means included in the driving means;
FIG. 10 is an elevation of the braking means from line 10--10 of FIG. 9;
FIG. 11 is a section to a larger scale along line 11--11 of FIG. 12, illustrating structure and operation of means providing a separable connection between the drive means of FIGS. 7 to 10 and drive means on the mast for the drilling head;
FIG. 12 is an end view of the female portion of the drive means of FIG. 11;
FIG. 13 is a side elevation, with parts broken away, of the lower portion of the mast showing, to a scale larger than FIG. 1, the means for driving the vertically movable drilling head, and means for facilitating loosening of threaded joints of drill rods;
FIG. 14 is an elevation of the apparatus viewed from the left of FIG. 13;
FIG. 15 is a plan view to an elarged scale of the drilling head and associated means for guiding it along the mast;
FIG. 16 is a sectional elevational view along line 16--16 of FIG. 15, to the same scale;
FIG. 17 is a side elevation to a scale larger than FIG. 3 of mechanism for moving the drilling head along the mast;
FIG. 18 is a view, partly broken away, of the mechanism from the left of FIG. 17;
FIG. 19 is a side view, to a scale larger than any heretofore used of a drill rod embodying the invention that can be advantageously used in the illustrated apparatus;
FIG. 20 is a section along line 20--20 of FIG. 19, to the same scale;
FIG. 21 is a section along line 21--21 of FIG. 19, to the same scale;
FIG. 22 is a vertical section along line 22--22 of the lower end of the drill rod of FIG. 19, to the same scale;
FIG. 23 is a side view of the drill rod storage and handling apparatus, no drill rods being shown in this view for the sake of clarity;
FIG. 24 is a side view of the lower portion of the apparatus of FIG. 23, to a larger scale;
FIG. 25 is a section along line 25--25 of FIG. 24 and to the same scale;
FIG. 26 is a plan view along line 26--26 of FIG. 23 of the lower portion of the rotatable drill rod storage rack, for holding the drill rods at the lower end of the rack, the scale being larger than that of FIG. 24;
FIG. 27 is a vertical sectional view along line 27--27 of FIG. 26 and to the same scale;
FIG. 28 is a plan view along line 28--28 of FIG. 23 to the scale of FIG. 26, of the upper portion of the rack, for holding the drill rods at the upper end of the rack;
FIG. 29 is a view from line 29--29 of FIG. 23, showing the relationship of the upper and lower drill rod holding portions of the rack;
FIG. 30 is a bottom plan view of the lower rod holding portion of the rack, and a portion of the means for rotating the rack to predetermined positions;
FIG. 31 is a plan view of means mounted on a lower portion of the mast for engaging a drill rod to prevent its rotation when a threaded member above it is being unscrewed, the scale being considerably larger than that of FIGS. 13 and 14;
FIG. 32 is a side view of FIG. 31, with parts sectioned;
FIG. 33 is a plan view of breakout means turning a drill rod to loosen a threaded connection of the drill rod to an adjacent element, the scale being smaller than that of FIGS. 31 and 32;
FIG. 34 is a side elevation of FIG. 33 apparatus;
FIG. 35 is a section along line 35--35 of FIG. 36, showing another means for forming a separable driving connection between the drive means on the vehicle and that on the mast, and that can be used in place of the means shown in FIGS. 11 and 12;
FIG. 36 is a section along line 36--36 of FIG. 35;
FIG. 37 is a section along line 37--37 of FIG. 36 and to a larger scale;
FIG. 38 is an end view to the scale of FIG. 37 of the projecting portion of the driven member of FIG. 35;
FIG. 39 is a side elevation of another form of drill rod embodying the invention that may be used in the drill string;
FIG. 40 is a section along line 40--40 of FIG. 39;
FIG. 41 is a section along line 41--41 of FIG. 39;
FIG. 42 is a plan view of the lower portion of another drill rack embodying the invention that may be used in place of that shown in FIG. 26 and associated Figures;
FIG. 43 is a plan section, to a scale larger than that of FIG. 42, of one of the cup members, with a drill rod in it that is engaged by the latch member of the cup member;
FIG. 44 is a section along line 44--44 of FIG. 42, to a larger scale, one of the cup members of FIG. 42 for holding the lower end of a drill rod, the cup member being empty of a drill rod; and
FIG. 45 is a view along line 45--45 of FIG. 44 showing an inclined surface of the latch member that causes it to retract when a drill rod enters the cup member.
DESCRIPTION OF PREFERRED EMBODIMENTS
Apparatus
The drilling apparatus illustrated in FIGS. 1-34 as embodying the invention comprises mobile vehicle 1 carrying drilling means 2.
Drilling means 2 comprises a rigid mast 3 that is pivotally mounted on the rear end of vehicle 1 and adapted to be raised to an upright drilling position (FIGS. 1-5) and to be lowered to a horizontal traveling position (FIG. 6). Mast 3 carries a drilling head 4 mounted for movement in a guided path longitudinally of the mast and adapted when the mast is in its upright position to rotate, lower and raise along a drilling axis A, a drill string S made up of end-connected hollow drill rods R, the lowermost of which carries suitable cutter bit H (FIGS. 3-4).
Mast 3 also carries drill rod storage and handling apparatus 5 adapted to store a plurality of drill rods R, and, as required, to move them into alignment with the drilling axis to permit them to be individually connected to and disconnected from drilling head 4, and to store drill rods as required.
Drilling head 4 is rotated as required by a driving or kelly bar 6 mounted for rotation about a fixed axis B in the mast 3, head 4 being adapted to slidably but not rotatably engage such bar. Bar 6 is rotated from a gear box 7 rigidly fixed to the mast. Drilling means 2 also includes a known shroud 8 that is fixed to the bottom of the mast and adapted to extend to the ground around the bore hole to collect dust and dirt blown upwardly by air supplied under pressure through the interior of the strand of drill rods in a known manner. Drilling means 2 also includes, adjacent mast 3, a drilling control cab 9 from which an operator controls the drilling means and the drilling operation.
Mobile vehicle 1 comprises a rigid frame 10 adapted to be supported and transported in conventional manner, steerable front wheels 11 and rear driving wheels 12. The frame also carried hydraulically operated jacks 13, two at the sides of the rear end of the frame adjacent drilling means generally centrally of the front end of frame 10. The jacks are adapted to be extended downwardly as required to level the vehicle and stabilize it during the drilling operation (FIGS. 1-5) and be raised (FIG. 6) during travel of the vehicle.
The frame of the vehicle also carries at its rear end drilling control cab 9, and at its front end a driver control cab 14 and an internal combustion engine 15 of known type. The engine drives, through known shiftable transmission 16 controlled from cab 14, a drive shaft 17 that is connected to a known power divider gear box 18 adapted to be controlled from cab 14 to transmit power from engine 15 and shaft 17 to a drive shaft 19 for driving wheels 12 or to transmit power to a drive shaft 20 to a gear box 21.
Shafts 17, 19 and 20 have universal joints 23, 24, and 25. Gear box 21 is adapted to transmit power through shaft 26 to a known rotary air compressor unit 27 for supplying air under pressure to the interior of drill rods in the drill string, and to a known unit 28 for developing hydraulic fluid pressure for hydraulically operating parts of the drilling apparatus.
Gear box 21 (FIGS. 3, 8) also drives a shaft 29 from which driving bar 6 of the drilling means may be driven as required. Gear box 21 comprises a train of gears 31, 32, 33 and 34 by which shafts 26 and 29 are driven from shaft 20.
Shaft 29, having universal joints 35, is connected to a known clutch 36 having a driving member 37 and a driven member 38 actuated by fluid cylinder 39 controllable from cab 9. Clutch 36 is adapted when engaged to rotate a shaft 41 rotatably supported from frame 10 of the vehicle and connected by known torque-limiting coupling 42 to a reduction gear box 43 having output shaft 44 adapted to rotatably drive a disconnectible driving unit 45 described later. Shaft 41 rigidly carries a known disc brake element 46 (FIGS. 3, 7, 9, 10) adapted to be engaged by gripper 47 controlled from cab 9 and adapted to rapidly halt rotation of shafts 41 and 44 and parts driven by driving unit 45 to eliminate the inertial effects of the parts driven by clutch 36 and thereafter to hold these parts stationary.
Driving bar 6 of drilling means 2 (FIGS. 3, 13, 14, 15, 16) is connected and is driven from right angle drive gear box 7 having a driving stub shaft 48 driven from disconnectible driving unit 45 (FIGS. 3, 11, 12, 13, 14).
Unit 45 comprises a female driving member 51 mounted on output shaft 44 of gear box 43 and adapted to be engaged with and to drive a male driven member 52 fixed to stub shaft 48 of gear box 7 mounted on mast 3. Member 51 (FIGS. 11, 12) comprises a housing 53 fixed to a flange 54 4igidly mounted on shaft 44. An annular stop member 55 is clamped to the front of housing 53 by bolts 56. An axially movable driving element 57 is slidably mounted on bolts 56 and biased by springs 58 toward stop member 55 which limits travel of element 57. Element 57 has a polygonal-shaped opening 59 therethrough, the eight-cornered generally star-shaped opening illustrated being found preferable. The opening has beveled front edges 60.
Male driven member 52 on shaft 48 has a projecting portion 62 having an axially extending exterior contour 63 that is identical with but slightly smaller than that of opening 59 and that has a beveled edge 64 at its free end. Consequently as mast 3 is raised to its upright position, portion 62 of driven member 52 engages movable driving element 57 of driving member 51. If it should happen that the polygonal contours of opening 59 and portion 62 are in identical relative angular positions, portion 62 will enter opening 59. However, if they are not in identical angular positions, as will usually be the case, the free end of portion 62 of driven member 52 and the outer surface of element 57 of driving member 51 will contact as shown in the upper portion of FIG. 11 and the driving element 57 will move axially inwardly of housing 53 of the driving member 51 as the axis of driven member 52 aligns with that of driving member 51 as the mast 3 moves to its final upright position. Then, as member 52 rotates when power is supplied and clutch 36 is engaged, portion 62 of driven member 52 will snap into polygonal opening 59 of driving member 51 to provide positive driving engagement between the driving and driven members, and hence positive rotation of driving bar 6 (FIGS. 11-16), the beveled edges of portion 62 and opening 59 facilitating entry of portion 62 into opening 59.
As shown in FIGS. 1-6, 13 and 14, the mast 3 is a rigid structure comprising longitudinal members 65 at the rear of the mast, longitudinal members 66 at the front of the mast, rear member 67, and bracing members 68, all rigidly connected together. The mast is connected by a pair of pivot structures 69 to the rigid vehicle frame 10 and is adapted to be raised to its upright position (FIGS. 1-5) and lowered to its traveling position (FIG. 6) by means of a pair of fluid powered cylinders 70. The mast includes cross members 71 to which gear box 7 is rigidly connected, and a bottom plate, 72 which carries guide 73 for the drill rods in the drill string as it drills into the earth; plate 72 also carries dirt shroud 8 and other mechanism to be described later for loosening drill rods.
The front members 66 of the mast and rear member 67 rigidly fixed in the mast centrally between and parallel to rear members 65 (FIGS. 1, 2, 4, 15, 16) act as guide members to support and guide drilling head 4 for movement in an upright path along the mast when the mast is upright. Drilling head 4 carries front guide means 74 and 75 (FIGS. 15, 16) that move along front frame members 66. Guide means 74 comprises bracket structure 76 that is fixed to one side of head 4 to extend laterally and longitudinally of the head. This bracket carries two longitudinally spaced rollers 77 that are rotatable about axes normal to the path of movement of the head 4 and that contact one side of associated member 66; this bracket also carries two other longitudinally spaced freely rotatable rollers 78 each having a V-shaped peripheral groove that engages the outer V-cross sectioned surface of a guide strip 79 on the other side of such member 66 to guide head 4 laterally relative to the member 66. Drilling head 4 also carries a rear guide member 80 that slidably engages both sides of rear guide member 73 to prevent lateral movement of the rear end of head 4.
The other guide means 75 comprises another bracket structure 76 fixed to the other side of head 4 and carrying pairs of longitudinally spaced freely rotatable rollers 81 and 82 engaging opposite sides of the other member 66. Therefore, drilling head 4 is accurately guided for movement in a fixed path relative to members 66 of the mast.
Drilling head 4 (FIGS. 1-4, 16, 17) comprises a rigid housing 83 to which brackets 76 are fixed. A sleeve 84 is mounted in the housing for rotation about an axis B parallel to the drilling axis A. The sleeve has a through opening 86 of polygonal cross section, square in the illustrated embodiment, that matches the cross section of the driving bar 6 but permits the head 4 to move slidably along the bar. Inside housing 83, sleeve 84 rigidly carries a gear 85 engaging idler gear 86 that engages a gear 87 rigidly mounted on a spindle 88 rotatably mounted in housing 83 (FIG. 16). An adapter spindle member 89 (FIGS. 1-4, 16-19) is bolted to spindle 88 and has at its lower end an internal tapered thread 90 adapted to engage a mating external tapered thread 91 on the upper end of associated drill rod R. Spindle 88, member 89 and the drill rods have connected longitudinal openings therethrough. The upper end of opening 93 in spindle 88 is connected to a suitable known fitting 94 to an air hose 95 (FIGS. 3, 16) connected to compressor 27 to supply air under pressure to the interiors of spindle 88, member 89 and drill rods connected to member 89 to blow out drilled material from drilled bore D in the earth.
Therefore, as driving bar 6 is rotated it positively rotates spindle 88 and any drill rods connected to member 89 fixed to the spindle, and drilling head 4 can move longitudinally of the mast while its spindle and attached drill rods are being so rotated.
Crowd mechanism 96 (FIGS. 17, 18) moves drilling head 4 downwardly to urge the drill rods in the drill string into the earth during the drilling operation, and upwardly to permit removal of the drill rods as required. At each side of mast 3, one end of a chain 97 fixed to the top of one of the brackets 76 at the sides of drilling head 4 and when the mast is in its upright position passes upwardly over a sprocket 98 and then downwardly and under another sprocket 99 fixed to a movable bracket 100 of actuating mechanism 101, the other end of the chain being fixed to the top of the mast. Also at each side of the drilling head, another chain 103 is fixed at one end to the bottom of the bracket 76 on drilling head 4 and passes downwardly under a sprocket 104 at the bottom of the mast, then upwardly over another sprocket 105 fixed to bracket 100, and has its other end fixed to the mast.
The actuating mechanism 101 at each side of the drilling head comprises the bracket 100, carrying sprockets 99, 105, fixed to the piston rod 106 of fluid actuated long travel cylinder 107 that provides a travel of the rod of essentially half the distance through which the drilling head moves. Sprockets 98 at the top of the mast are rigidly connected to a common drive shaft so that their rotary motion is coordinated; sprockets 104 are individually rotatable.
It is obvious that when piston rods 106 are extended from their cylinders 107, drilling head 4 is pulled down and causes the string S drill rod R connected to head 4 to penetrate the earth. When the piston rods are retracted into their cylinders head 4 is lifted and withdraws the drill rods from the drilled bore D.
Each of the drill rods R (FIGS. 19-22) handled by the drill rod handling means 5 comprises an elongated tubular body 108 the upper end of which has an external tapered right hand thread 91 of known configuration in this art and adapted to engage a mating internal thread of a connected drill rod or of coupling member 89 connected to drilling head 4; the lower end of body 108 has an internal tapered right hand thread 90 adapted to engage the external thread 91 of a connected drill rod or of cutter head H.
When the rod is in upright drilling position, body 108 has an external cylindrical portion 109 extending a substantial distance below upper thread 91 and having an external cylindrical portion 111 of reduced diameter located a short distance below upper thread 91 with an upper radial shoulder 112 between portions 109 and 111, reduced portion 111 containing a plurality, three in the illustrated embodiment, of axially extending equiangularly spaced elongated slots 113. Each slot 113 in cross section (FIG. 20) has a radial wall 114 and an intersecting wall 115 located at a right angle to wall 114, slots 113 being arranged so that when one of the walls 114 is engaged by a stop member rotation of the rod in a counterclockwise direction is prevented, thus permitting unscrewing upper thread 91 of a connected member such as a drill rod or member 89.
Body 108 has another external cylindrical reduced portion 116 near the upper end of the rod but a substantial distance below reduced portion 112, portion 116 being located immediately below larger cylindrical portion 109, radial shoulder 117 at the upper end of portion 116 separates portions 109 and 116. A plurality of axially extending equiangularly spaced longitudinal slots 118, three in the illustrated embodiment, are located at the lower portion of the rod at locations where they do not intersect internal thread 90. Each of these slots (FIGS. 19, 21, 22) has a rectangular cross section, axially extending sides 119 parallel to a radius of the rod, and a bottom 120 that is flat for a major portion of the slot length but having curved ends 121 extending from the flat bottom to the surface of the rod.
The rod also has an axial opening 122 extending longitudinally through the entire length of the rod from one end to the other to permit pressurized air to be fed through the rod to the bit H as described above. The rod is so designed that when it is connected to an adjacent rod or member 89 of the drilling head 4, a closed air-tight passage extends throughout the resulting drill string from drilling head 4 out through bit H.
The drill rod storage and handling means 5 of the illustrated apparatus comprises (FIGS. 1, 2, 23, 24, 26-30) a shaft 123 rotatably mounted on mast 3 about an axis X parallel to the axis A of spindle 88 that is also the drilling axis and adapted to be moved to and between two positions by fluid cylinder 124 connected between the shaft and the mast. Shaft 123 carries upper and lower laterally extending arms 125 and 126 that support a rack 127 for rotation about an axis Y parallel to axis X. Rack 127 is adapted to hold and carry several drill rods R and laterally move them so their axes can individually coincide with the drilling axis A as required. Rack 127 comprises a shaft 128 rotatably supported about axis Y from arms 125, 126.
The lower portion of the rack includes transverse lower supporting member 129 (FIGS. 23, 24, 26-30) fixed to shaft 128 and carrying socket means taking the form of a plurality of upwardly open cup members 130 each having a flared upper edge and adapted to receive and hold the lower end of a drill rod. In the illustrated embodiment, member 129 has four cup members 130 and also an opening 131 with a circular arcuate rear portion 132. The centers of the cup members and portion 132 are equiangularly spaced from and about axis Y. Opening 131 also has a side wall 133 extending essentially radially of axis Y, and a side wall 134 extending generally parallel to wall 133.
Each cup member 130 has, between its open upper end and its closed lower end, a radially extending rectangular cross sectioned housing 135 that slidably carries a latch member 136 that has a mating cross section and hence is non-rotatable. Member 136 thus is movable in a straight path between an extended position in which the inner end of member 136 projects substantially into the cup member and a retracted position in which the inner end does not so project into member 136, is biased by spring 137 inwardly toward the cup member interior such inward movement being limited by stop 138 engaging the outer closed end of housing 135. The inner end of member 136 has a side surface 139 parallel to the radial axis of member 136 and the axis of the cup member 130, a side surface 140 parallel to the axis of the cup member and inclined toward the end of member 136, and an inclined top surface 141 that can be engaged by the bottom of a drill rod to force member 136 outwardly to permit the lower end of the drill rod to be fully inserted into the cup member. After such insertion, the inclined side surface 140 causes the latch member to retract and ratchet to permit rotation of the drill rod in a clockwise direction in the cup member, but the radial side surface 139 prevents rotation in a counterclockwise direction by contact of such surface with a side surface 119 of a slot 118 in the lower end portion of the drill rod when the latch member is extended.
Rack 127 also has an upper laterally extending rigid supporting member 142 (FIGS. 23, 28, 29) that is rigidly fixed to the upper portion of shaft 128, and that laterally supports the upper portions of drill rods in the rack and permits their removal from the rack. Member 142 has four identical generally radially extending outwardly opening slots 143 and a single generally radially extending outwardly open slot 144 of different and wider configuration. Slots 142 and 143 have inner circular arc portions the centers of which are equidistantly and equiangularly spaced about axis Y of the rack 127. Each of slots 143 has an inner portion 145 that is an arc of a circle greater than a semi-circle and of a diameter slightly larger than the maximum diameter of the cylindrical portion of the drill rod body 108 of rod R between reduced portions 111 and 116, and a neck portion 146 extending from circular portion 145 to the periphery of member 142 and of a width slightly larger than the diameter of reduced portion 116 of rod R but substantially smaller than the diameter of the larger rod portion 109 between reduced portions 111 and 116. Radially extending slot 144 has an inner portion 147 of semicircular configuration and of preferably slightly larger radius than portions 145 of slots 143 and a neck portion formed by straight side walls 148 and 149 that extend outwardly from circular portion 142 to the periphery of member 142 and essentially parallel to the radius of member 142 between axis Y and the center of circular arc portion 147. The centers of circular portions 145 and 147 of slots 143 and 144 are equidistantly and equiangularly spaced from and around axis Y. Moreover, the centers of circular portions 145 of slots 143 of upper member 142 are aligned in rack 127 with the centers of the circular cross sections of cup members 130 of lower supporting member 129 of the rack, the center of circular portion 147 of slot 144 in member 142 is aligned with the center of the circular portion of slot 131 in member 129, and the sizes and alignment of slots 131 and 144 are identical, as is apparent from FIG. 29.
The means for rotating rack 127 about its axis Y comprises (FIGS. 23-25, 30) a geneva wheel mechanism 150 comprising a geneva start wheel member 151 fixed to the lower end of shaft 128 above arm 126. Member 151 has a number of radially extending outwardly open slots 152 equal in number to the number of cup members 130 of member 129 and to the number of slots 143 of member 142. Member 151 also has intermediate curved peripheral portions 153 and 154. Portions 153 constitute arcs of a circle and are shaped to fit the exterior circular arc portion 155 of the periphery of a rotatable actuating member 156 having actuating arm 157; portion 155 constitutes the major part of a circle. Curved portion 154 has a radius slightly larger than that of curved portions 132 of slots 131 and 144 of members 129 and 142. Slots 152 are all identical and equidistantly spaced from axis Y of the storage rack. Each slot 152 is symmetrical around a radius extending laterally from axis Y and these radii of slots 152 and the radius on which lies the center of circular arc portion 154 are equiangularly spaced from each other. Arcuate peripheral portions 153 of member 152 are identical and equidistantly spaced from the axis X and equiangularly spaced between end slots 152.
The relationship of the locations of slots 152 and curved portions 153 of geneva wheel member 151 to the cup members 130 of lower supporting member 129 of the rack 127 and to the slots 141 of upper supporting member 141 of the rack are shown in FIGS. 29 and 30. It is apparent that the radial axes of slots 152 are aligned with those on which lie the centers of cup members 130 of member 129 and the centers of curved slot portions 147 of member 141, and that the centers of the curved portion 132 of slot 131 of member 129 and curved portion 147 of slot 144 of rack member 142 are aligned with the center of curved portion 152 of geneva wheel member 151.
Arm 157 of actuating member 156 carries a roller 158 adapted to be engaged in the slots 152 of geneva wheel member 150 (FIG. 25). Actuating member 156 is fixed to, and positively rotated as required by, shaft 159 rotatably supported by arms 160 rigidly connected to supporting shaft 123 of rack 127. Shaft 159, and hence actuating member 156, is rotated as required by a fluid powered motor 161 supplied as required with fluid under pressure by unit 28 through known conduit means not shown and controlled from drilling control cab 9. By suitable actuation by motor 161, the geneva wheel mechanism can turn the rack about axis Y to individually bring each cup member 130 of lower supporting member 129 and its associated aligned slot 142 of upper supporting member 141 to a position where the axis of a drill rod in such cup and slot, which is essentially the axis along which the cup member and slot are aligned, is aligned with the drilling axis A, after the rack has thereafter been bodily moved about axis X. The action of the geneva wheel mechanism is such that it rotates rack 127 about its axis Y to exactly the proper location for this purpose, by interaction of arm 157 and of its roller 158 of actuating member 156 in the appropriate slot 152 of the geneva wheel member 151 and by interaction of the exterior circular arc portion 155 of the actuating member with the appropriate arcuate peripheral circular arc portion 153 of the geneva wheel member to halt rotation of the rack at the proper angular location about axis Y. Despite the large sizes and weights of drill rods in the rack and the resulting large inertial forces caused by the weights of such drill rods and of the rack, the geneva wheel mechanism positively starts movement of the rack about axis Y, positively moves the rack about such axis, and accurately and positively halts movement of the rack as required for proper positioning of the selected aligned cup member 13 and slot 142.
Means is also provided to hold the rack 127 in the proper position after the rack has been rotated about its axis Y and after the rack has thereafter been bodily moved about axis X on the mast, to cause a selected cup member 130 and its aligned slot 142 to have their common axis aligned with drilling axis A as described above. Such holding means includes radially extending projections 163 on the periphery of lower supporting member 129 of the rack (FIGS. 26, 29, 30) located so each of such projections is adapted to mate with a mating notch 164 on a lug 165 fixed to a frame member 166 at the lower end of the mast, after the rack is properly located, to hold the rack in its proper position and thus to hold the selected rod in proper position.
The illustrated apparatus also includes (FIGS. 13, 14, 31, 32) wrench means 167 for loosening a threaded joint between a lower drill rod and an upper element threaded onto the upper end of the drill rod, such as another drill rod or spindle member 89 connected to the drilling head 4, and for supporting the lower drill rod after it is disconnected from the upper element. Wrench means 167 (FIGS. 31, 32) comprises a base member 168 fixed to the bottom plate 72 of the mast, and a movable drill rod-engaging member 170 comprising a plate 171 slidably supported on member 168 and adapted to be moved toward and away from the drilling axis A and the drill rod centered on the axis, by a fluid powered cylinder 172 connected to member 168 and having a piston rod 173 connected to plate 171. Plate 171 has at its front end a concave recess 174 of curved configuration adapted to engage the reduced portion 111 near the upper end of a drill rod in the ground, so that the upper surface of edge of opening 174 plate 171 can engage the shoulder 112 at reduced portion 111 to support the drill rod during and after the loosening operation.
Member 170 also includes a latch member 175 that is mounted on and reciprocable relative to plate 171 in a path transverse to drilling axis A, being slidably but nonrotatably supported in a housing 176 of rectangular cross section that is fixed to plate 171 and matches the cross section of member 175. Latch member 175 is fixed to a rod 177 that extends through the rear wall 178 of housing 176 and has near its free end a stop member 179 that by engagement with wall 178 limits outward movement of the latch member. The latch member is biased toward the drilling axis by compression spring 180. Latch member 175 has a flat side surface 181 adapted when the member is extended to engage the radial wall 114 of a notch 113 in reduced portion 111 of the lower drill rod and prevent rotation of the rod when it is urged to rotate in an unscrewing direction which is counterclockwise in the illustrated embodiment. The latch member also has an inclined side surface 182 that can contact the intersecting inclined side walls 115 of the notches 113 in the drill rod and be forced to retract to permit rotation of the rod in the opposite direction which is clockwise in the illustrated apparatus.
Consequently, when it is desired to loosen and disconnect the threaded joint between a lower drill rod and an upper element such as an upper drill rod or spindle member 89 of drilling head 4, the lower drill rod is lifted by raising the drilling head until such drill rod is in the position shown in FIG. 32, so that shoulder 112 of reduced portion 111 of the lower rod R is slightly above the tops of drill rod engaging plate 171 and latch member 175. Fluid cylinder 172 is then actuated to move plate 171 so its recess 174 contacts the side of reduced portion 111 of the rod under shoulder 112, thereby causing latch member 175 to engage portion 111 of the drill rod, usually on the curved surface of portion 111, so the latch member is pushed back against the spring 180. The upper element and lower drill rod are then rotated by the drill head 4 in the unthreading direction, or counterclockwise in the illustrated case; latch member 175 is forced outwardly by spring 180 to enter one of the slots 113 of the lower drill rod and engage radial wall 114 of such slot, to prevent further rotation of the rod in such direction. Then, after the threaded joint between the lower drill rod and the upper element is loosened and rotation of the upper element is continued, the lower drill rod is held against rotation so that the upper element is unscrewed from the lower drill rod. The lower drill rod and any drill rods connected to it below it are then supported by plate 171 engaging shoulder 112 of the rod, so that the lower drill rod thus is located where it can be engaged and screwed onto the spindle member 89 of the drilling head 4 so such drill rod can be raised and disconnected in a like manner from a still lower drill rod and removed by rack 127 from the drilling axis, or where it can have another drill rod connected to its upper end, as described later.
For those situations in which it is desired to disconnect an upper drill rod from a lower drill rod and the threaded joint between these rods is so tight that the drilling head 4 cannot loosen such threaded joint because the threaded joint between the upper rod and the spindle member 89 would loosen first, the auxiliary loosening means 182 (FIGS. 13, 14, 33, 34) is provided.
Means 182 is mounted above wrench means 167 on the mast 3; it comprises a fluid cylinder 183 that extends laterally of the mast and the drilling axis A and is fixed to member 71 at the rear of the mast, and has a piston rod 184 carrying at its outer end drill rod-engaging means 185. Means 185 comprises a flexible chain 186 fixed to a holding member 187 mounted on rod 184 and having a concave curved surface 188 shaped to fit and mate with the outer curved surface of the drill rod and also an arcuate channel 189 adapted to receive the outer end of chain 186. The arc of channel 189 is formed around a radius extending through the axis of the drill rod when the member 187 engages the rod. The cylinder 183 is located to a side of the drill rod so that when its piston rod is extended and chain 186 is in channel 189, and member 187 bears against the drill rod as shown in FIG. 33, the rod and chain are substantially tangential to channel 189. The holding member 187 also includes a rigidly mounted latch portion 190 that is adapted to fit closely in one of the longitudinal slots 118 as the lower end of a drill rod, as shown in FIG. 33.
Cylinder 183 is connected by suitable known conduits 191 to the fluid pressure unit 28 and to control means either in cab 9 or at a suitable location near the cylinder.
When it is desired to loosen the threaded joint between a lower drill rod R and an upper drill rod immediately above it, the lower drill rod is located and then engaged by wrench means 167 to prevent unthreading rotation of the rod, as previously described. Piston rod 184 of loosening mechanism 182 is then extended, and holding member 187 manually placed so its curved surface 188 contacts the outer surface of the upper drill rod and so its latch portion 190 extends into a lower slot 118 of the upper drill rod remote from cylinder 183 of means 182. Cylinder 183 is then controlled to retract the piston rod 184, thus causing the upper drill rod R to rotate in an unthreading direction while the lower drill rod is prevented from rotating, so that the threaded joint between the drill rods is loosened. The upper drill rod can then be completely disconnected from the lower drill rod by further rotation and movement of the drilling head, while the lower drill rod is held by wrench means 167 as previously described.
The apparatus includes conventional means, not shown, for locking the mast 3 in its upright position. The apparatus also includes conventional conduit means for supplying hydraulic fluid under pressure from pressurizing unit 28, to cylinder 40 for raising and lowering the mast 3, to cylinders 107 of the crowd mechanism 96 for raising and lowering the drilling head 4 on the mast, to cylinder 124 for rotating shaft 123 and swinging rack 127 about axis X on the mast, to fluid motor 161 for actuating the geneva wheel mechanism to rotate rack 127 about its axis Y, and to cylinder 183 of loosening means 182. The apparatus also includes known control means operated from cab 9, and from other locations if desired, for controlling the operation of each of the above indicated hydraulic fluid powered elements. The apparatus also includes conventional means for supplying air under pressure from compressor 27 to the drilling head 4 from which it passes into the drill rods connected to the drilling head, and for controlling the flow of such air from cab 9. Controls for controlling operation of engine 15 are also in cab 9 as well as in cab 14.
Suitable known means, not shown, is also provided to limit the travel of the drilling head at the upper and lower ends of its path of travel on the mast 3.
The apparatus can be adapted to handle drill rods of smaller diameters by inserting suitable adapter sleeves in cups 130 of lower rack member 129, and inserting into slots 143 of upper rack member 142 suitable adapter elements having smaller slots and necks; if the thread size of the drill pipe is smaller, a suitable spindle member 89 can be replaced on the drilling head with a spindle member having a suitably smaller thread.
Operation
The above apparatus of FIGS. 1-34 may be operated as follows, assuming that the apparatus has been moved to the desired location, that the jacks 13 have been extended to level the apparatus, that the mast has been raised to its upright position and locked in that position, and that gear box 18 is set to transmit power to the drilling means and not to the wheels of the vehicle. It is also assumed that rack 127 contains the maximum number of drill rods, four in the illustrated embodiment, positioned in the rack with their lower ends in cup members 130 of lower member 128 and with their upper larger diameter portions, those above reduced portions 116, extending through slots 143 of upper member 142 of the rack that are aligned with the cup members in which the rods are located, these larger diameter portions of the drill rods having diameters larger than the necks 146 of the slots 143 so that the upper portions of the drill rods are secured against lateral movement out of the slots in the rack (FIGS. 1, 2, 6, 19, 28). There is also another drill rod connected to the spindle member 89 of the drilling head 4; this rod has cutter bit H.
Engine 15 is then started and controlled to operate at low speed, transmission 16 is shifted to low speed to provide power in the direction of rotation proper for drilling, and clutch 36 is actuated to cause driving bar 6 to actuate driving head 4 to rotate the drill rod in drilling direction.
The crowd mechanism 96 for moving the drilling head 4 longitudinally along the mast, is then actuated at low pressure and slow speed until the bit H contacts the earth. The air is then turned on to supply pressurized air to the drill rod connected to the drilling head, and the speed of rotation of such rod is increased by increasing the speed of the engine, and the speed of movement downwardly of the drilling head 4 is increased by increasing pressure in cylinders 107 of mechanism 96 to achieve desirably rapid penetration. As drilling progresses, the air passes downwardly through the drilling head, member 89, the connected drill rod, and bit H into the drilled hole and then upwardly around the drill rod and out of the drilled hole into shroud 8 carrying with it, from the drilled hole, dust and other debris, that is collected in the shroud.
After the drilling head 4 has traveled downwardly to its maximum length of stroke, and if it is desired to add another drill rod, the air to the drill rod connected to head 4 is shut off and the drilling head raised out of the drilled hole until the upper reduced portion 111 of the rod is in the position shown in FIGS. 31, 32, where portion 111 can be engaged as described above by the drill rod engaging member 170 of the lower wrench means 167. Transmission 16 then is shifted to reverse the direction of rotation at slow speed, causing the drill rod to rotate in the unthreading position and causing latch member 175 of member 170 to engage slot 113 in the drill rod and halt its rotation. By manipulation of clutch 36 the spindle member 89 is caused to continue to rotate, thus loosening the joint between the drill rod and the spindle member and causing it to begin to unscrew from the thread at the top of the drill rod. Hydraulic fluid at low pressure is applied to cylinders 107 of mechanism 96 to cause the drilling head to raise slowly and allow the spindle member 89 to unscrew from the drill rod without binding. After the spindle member has completely separated from the drill rod the drilling head is rapidly raised to the top of its travel on the mast.
While the drilling head is thus moving up on the mast, transmission 16 is shifted to low speed in the drilling direction of rotation, and preferably suitable joint compound is applied to the thread of the drill rod held by the lower wrench means.
Rack 127 is then caused to move by actuation of mechanism 150 to bring a selected one of the drill rods R in the rack into proper position to be connected to the spindle member after the rack is swung about axis X as follows. The rack then is swung about axis X by actuation of cylinder 124 so that the selected drill rod which had been moved by geneva mechanism 150 will be located under and coaxially with spindle member 89 of drilling head 4, the rack being firmly located in such position by engagement, with notch 164, of the projection 163 on member 129 of the rack corresponding to the selected drill rod. Clutch 36 is then engaged to cause the drilling head spindle member 89 to rotate at low speed and the drilling head is lowered by low pressure in the cylinders 107 of crowd mechanism 96 to cause the female thread of the spindle member to engage the male thread at the top of the selected drill rod in the rack. The weight of the drill rod and resisting friction between the drill rod and the rack holds the drill rod against rotation with the threaded joint between spindle member 89 and the rod is tight. After such threaded joint is tight the drill rod will rotate in its cup member 130 by ratcheting action between slots 118 in the lower portion of the rod and the latch member 136 of the cup.
After the joint is tight, which is indicated by the ratcheting action, drilling head 4 is raised to raise the spindle member and its selected drill rod from the rack to a position where the reduced portion 116 at the upper portion of the drill rod is aligned with the neck 146 of the slot in upper member 142 of the rack in which the drill rod is disposed. The lower curved ends of slots 118 at the lower end of the rod facilitate disengagement of the latch member of the cup as the rod is thus raised. Cylinder 124 is then actuated to cause the rack 127 to swing back about axis X to its retracted position, clearing the drill rod which is located at this time so that its reduced portion 111 clears the neck 146 of the slot in member 142 of the rack and the lower end of the rod clears the top of the associated cup members 130.
With the rack thus retracted, the drill rod attached to the spindle member 89 is then rotated in the threading position, clockwise in the illustrated embodiment, while being lowered so that its female thread at the bottom of the drill rod engages the male thread at the top of the drill rod held by wrench means 167. When the joint between these drill rods is tight, member 171 of wrench means 167 is retracted to release the lower drill rod, and the apparatus is then in condition for continued drilling.
Transmission 16 is then shifted to the desired gear, the air pressure is turned on to supply air through the connected drill rods which are so tightly connected that there is no air leakage. The engine speed is brought up to drilling speed, clutch 36 engaged to rotate the thus connected drill rods, and the pressure in cylinders 107 of mechanism 96 is increased and adjusted as necessary to cause the cutter bit to penetrate the earth and drill the hole. This procedure may be continued as long as desired, drill rods being thus connected to form a drill string as long as drill rods are available in the rack 127 for the desired depth of hole.
After the desired depth of drilling has been achieved and it is desired to remove the drill rods from the drill string, the following procedure may be followed. Drilling head 4 and its attached string of drill rods is raised on the mast to the location where wrench means 167 may be engaged as described above with reduced portion 111 at the upper end of the lower drill rod that is attached to the bottom end of the upper drill rod connected to the spindle member 89 of the drilling head member 170. The air pressure is shut off. Clutch 36 is disengaged to halt rotation of the drill rods. Wrench means 167 is then engaged with the stationary lower drill rod at its reduced portion 111 as described above. Piston rod 184 of loosening means 182 is then extended and its holding member 187 is manually appropriately adjusted to contact the surface of such drill rod and to have its latch portion 190 extend into the appropriate slot 118 at the lower end of the upper drill rod that is connected to the spindle member. Piston rod 184 is then retracted in its cylinder to loosen the joint between the upper drill rod and the lower drill rod; if necessary one or two additional manual connections may thus be made between the means 182 and the drill rod to achieve desired loosening. Member 187 and latch 190 are then disconnected from the upper drill rod. Transmission 16 is then shifted to reverse rotation of the spindle member 89, clutch 36 is engaged, and the drill rod connected to the spindle member is unthreaded from the lower drill rod held by wrench means 167, while the drilling head is slowly raised with low pressure in cylinders 107 to permit ready unthreading without binding.
After the upper drill rod still connected to the spindle member 89 is completely disconnected from the lower drill rod, it is raised upwardly by the drilling head 4 on the mast to the height mentioned below. Rack 127, which if necessary had been previously rotated by mechanism 150 about rack axis Y, is swung about axis X to bring an empty slot 143 of member 142 and its aligned empty cup member 130 of member 129 into alignment with the drill rod supported by the drill spindle, the height of the drill rod having been previously adjusted so that the neck of the empty slot 143 can pass around the reduced portion 116 near the upper end of the drill rod so that the drill rod can completely enter the slot 143. Drilling head 4 is then slowly lowered while the drill rod connected to the spindle member is rotated in reverse or unthreading position, or counterclockwise in the illustrated embodiment. Such lowering is continued until the lower end of such drill rod bottoms in the cup member 130 aligned with the rod, and the upper enlarged portion of the drill rod above its reduced portion 116 moves axially of the rod into the inner portion of the slot 143, so that such upper portion of the drill rod cannot pass laterally out of the slot and the upper portion of the rod is thus secured against movement laterally relative to the rack. As rotation of the spindle member and rod is continued, the latch member 136 of such cup member engages the longitudinal wall 119 of one of the slots 118 at the lower end of the drill rod, thus halting rotation of the rod. Continued rotation of the spindle member 89 by the drilling head unscrews the spindle member from the upper end of the drill rod in the rack; as the spindle member is rotated it is desirable that the drilling head be raised slowly to provide the proper unscrewing action without binding. After spindle member 89 is completely disconnected from the drill pipe, the drilling head 4 is moved to its extreme upper position on the mast, and rack 127 is swung about axis X out from its position under the spindle member and to its retracted position.
The drilling head is then moved down on the mast with fast travel, while the transmission 16 is shifted to slowly rotate the spindle member in the threading or clockwise direction in the illustrated embodiment. The spindle member then is threaded onto the end of the drill rod that is held by wrench means 167, while the spindle member is moved downwardly with low pressure in the cylinders of mechanism 96. After the thus formed threaded joint is tight, the wrench means is disconnected from the lower drill rod. If additional drill rods are to be disconnected, the procedure described above is repeated until all previously connected drill rods are thus removed and placed in the rack. In each case, after rack 127 has been retracted, the actuating mechanism 150 is caused to rotate the rack about its axis Y to bring a proper empty cup member 130 and aligned empty slot 143 into position so that when the rack is moved forward about axis X such empty cup member and slot can be aligned with the drilling axis to receive another drill rod.
Various modifications may be made in the apparatus and methods of operation described above.
FIGS. 35-38 illustrate a modified disconnectible driving unit 193 that may be used in place of driving unit 45 of the previously described embodiment, to provide driving action between output shaft 44 of the driving means mounted on the frame 10 of the vehicle 1, and stub shaft 48 of right angle gear box 7 that rotates driving bar 6 to cause drilling head 4 to rotate the drill rods in the drill string.
Unit 193 comprises a female driving member 194 mounted on output shaft 44 and adapted to be engaged with and to drive a male driven member 195 fixed to shaft 48 of gear box 7 on mast 3. Member 194 comprises housing 196 rigidly mounted on shaft 44. An annular stop member 197 is clamped to the front of the housing by bolts 198. An axially moving movable driving element 199 is slidably mounted on bolts 198 and biased by spring 200 towards member 197 which limits travel of element 199. Element 199 has an opening 201 therethrough the star-shaped opening with eight corners 202 illustrated being found advantageous. The opening has beveled front edges 203 at the front face 204 of element 199.
Driven member 195 has a projecting portion 205 with a front end 206 and an axially extending exterior contour 207 that in this embodiment is generally square in cross section and proportioned so that when portion 205 is fully inserted into opening 201 of element 199, its four corner portions extend into four of the corners 202 of opening 201 as shown in FIG. 36. The contour of opening 201 is such that portion 204 can fit in any group of alternate corners 202. Consequently, as the mast 3 is raised to its upright position, portion 205 of member 195 engages movable driving element 199 of driving member 194. If it should happen that the contours of opening 201 and of portion 205 are angularly aligned as in FIG. 36, then portion 205 will immediately fully enter opening 201. However, if they are not in such angular positions, as will usually be the case, end 206 of portion 205 and face 204 of 199 will contact and element 199 will be forced axially inwardly of housing 196 as the mast moves to its final upright position and the axis of driven member 195 aligns with that of driving member 194. Then, as member 194 rotates as power is supplied and clutch 36 is engaged, portion 205 of driven member 194 will snap into the opening 201 of driving member 193 and provide positive driving engagement between the driving and driven members and hence positive rotation of the driving bar 6 as described above.
In order to insure that the driving and driven members will not inadvertently disconnect under load, particularly if the engaging surfaces of element 199 and portion 205 wear over a period of time, the inner surfaces of opening 201 of driving element 199 that engage the outer surfaces of the corners of projecting portion 205 of driven member 195 as the parts rotate under drilling load, are shaped to provide a backdraft or inclination of each of such surfaces relative to the axis of the members when engaged.
Thus, as shown in FIGS. 35, 36, 37, in driving element 199 the surfaces 208 of the re-entrant corners 202 of the opening 201 that engage the outer surface of portions 209 of the projecting portion 205 of driven member 195 when the parts are rotating while under driving load, are inclined slightly to the axis of driving member 194 from front face of element 199 rearward and outwardly of element 199, so that at these surfaces opening 201 enlarges from the front to the rear of element 199.
The surface portions 209 at the corners of projecting portion 205 of driven member 195 are inclined from the front end 206 of the portion inwardly toward the rear of the member, as shown in fIGS. 35 and 38.
Consequently, when members 194 and 195 are engaged under load, the contacting inclined surfaces 208 of the driving element 199 and surfaces 209 of portion 205 of driven member 195 cooperate to exert axial components of forces on the engaged parts that tend to hold them in engagement. Any tendency of element 199 under load to move axially in housing 197 away from member 195 to an extent where element 199 could disconnect from member 195 is therefore negated by the inclined engaging surfaces of these parts.
Another modification of the invention that may be used is the drill rod R', shown in FIGS. 39 to 41 inclusive. This drill rod is substantially similar to that shown in FIGS. 19 to 21 of the embodiment described above, except there is a single reduced or recessed portion 210 near the upper end of the drill rod, and no other portion of reduced cross section, other than lower slots to be described later, in the body of the rod between its end threads 90 and 91. This reduced portion is of a diameter less than the diameter of the cylindrical portion 211 above the drill rod and portion 212 below the drill rod. Reduced portion 210 has an upper shoulder 213 between portion 210 and upper larger portion 211, and also has spaced elongated slots 113 with radial and inclined walls 114 and 115, that in this embodiment are identical in shape and spacing with slots 113 of reduced portion 111 of the embodiment of FIGS. 19 to 22, as is apparent from FIGS. 39, 40. The drill rod also has lower slots 118 identical with slots 118 of the previous embodiment, each slot having parallel side walls 119, and a bottom 120 with curved ends 121. An internal passage 214 extends entirely through the drill rod. The rod also has, as in the previous embodiment, upper male threaded portion 91 and a matching lower female threaded portion 90.
In this drill rod, reduced portion 210 performs the functions of both reduced portions 111 and 116 of the drill rod R of FIGS. 19 to 22 inclusive. That is, reduced portion 210 is of a diameter sufficiently small to enable it to pass laterally through the neck portion 146 of any of the slots 143 of upper member 142 of the rack 127, and portion 211 above reduced portion 210 of such larger diameter that such portion fits closely but slidably within inner portion 145 of each slot 143 but cannot pass through the neck 146. Consequently, when there is a proper dimensional relationship between drill rod R' and the lower and upper transverse supporting members 129 and 142 of the rack 127, the drill rod can be held in an aligned cup member 130 and slot 143 of the rack, and when rod R' is lifted as described above in connection with prior rod R, the rack can be moved laterally so the rod passes out of the slot 143 through its throat 146 to permit lateral disengagement of the upper portion of the rod R' from the rack in a manner similar to that described previously. Furthermore, reduced portion 210, and its associated shoulder 213 and slots 113, of drill rod R' can be used to support the drill rod when it is in the earth by wrench means such as the wrench means 167 of FIGS. 31 and 32 in a manner described previously in connection with drill rod R.
Drill rod R' in some respects can be more advantageous than prior drill rod in that it is simpler to manufacture and has a somewhat greater strength because there is only one reduced portion near its upper end.
Drill rod R' may be operated in connection with loosening means 182 on the mast by use of the elongated slots 118 at the lower portion of the drill rod, as described previously in connection with drill rod R of FIGS. 19 to 22. Slots 118 can also be used to prevent rotation of the rod in one direction by engagement with a latch member when the lower end of the rod is in a cup member of the lower transverse supporting member of drill rod rack 127, as previously described.
Another modification that may be used involves a somewhat different construction of the lower transverse supporting member of the rack. In this modification (FIGS. 42-45) the lower transverse supporting member 216 fixed to shaft 128, is essentially similar to member 129 shown and described in connection with FIGS. 26 and 27, except that the upwardly open cup members are somewhat different. These cup members 217 in this embodiment are of the same general diameters, heights and spacing as cup members 130 of the previous embodiment, and each has a flared upper edge.
Each cup member 217 has between its open upper end and its closed lower end a generally rectangular opening 218 (FIGS. 42, 44). A latch member 219 is pivotally mounted on the exterior of the cup member adjacent such opening for lateral movement. The latch member is supported by pivot pin 220 the ends of which are fixed in spaced parallel supporting members 221 fixed to the exterior of the cup member, the latch member being located between and guided by such members for movement in a lateral path normal to the axis of the cup member. The latch member is biased toward the cup member by a spring 222 surrounding pin 220 and engaging the latch member and a stop member 223 extending through the supporting members.
Latch member 219 has an inwardly projecting portion 224, having a generlly radial stop surface 225, that can extend through opening 218 into cup member 217, and an external stop portion 226 adapted to engage the exterior of cup member and limit inward travel of the latch member. The latch member also includes an inclined side surface 227 (FIGS. 43, 44, 45) extending from the extremity of stop surface 225 outwardly toward its pivoted end. Furthermore the inwardly projecting portion 224 has a surface 228 inclined downwardly and inwardly toward the juncture of surfaces 225 and 227, approximately 45° from the vertical in the illustrated embodiment, to permit the latch member to be forced outwardly to clear the interior of the cup member when the bottom end of a drill rod is inserted into the cup member.
The dimensions and shape of the latch member are such that the stop surface 225 of the latch member can engage a side of the lower slot 118 of a drill rod R or R' in the cup member and prevent its rotation in a counter-clockwise direction, to permit the drill rod to be held against rotation when the spindle member 89 is being unthreaded from the drill pipe as previously described; and also to permit the drill rod to rotate clockwise by ratcheting of the latch member as necessary by contact of the drill rod with side surface 227 when the spindle member 89 is being threaded onto the top end of a drill rod while its inner end is in the cup member, as described above.
Moreover, the pivot pin 220 has transverse notched or reduced portions 229 (FIG. 44) that permit the latch pin to break by shearing at either or both of these locations and cause the latch member 219 to disengage from the drill rod to prevent damage to the apparatus, in the event that the threaded joint between the upper end of the drill rod and the spindle member 89 should be so tight that it will not readily come unthreaded when the spindle member is rotated in the unscrewing direction, and in the event that another torque limiting element such as torque limiting coupling 42 does not operate to limit the torque exerted by the rod to below that exceeding the maximum load predetermined by the pin. Such shearing action therefore provides an added safety factor in preventing harmful damage to the apparatus. Shear pin 220 can be readily replaced, and the latch member readily re-installed, in the event the pin is thus broken under overload.
It is apparent that various other modifications may be made in the apparatus and methods of operation described above. Thus, different types of drill rod than those illlustrated may be used in connection with a rack rotatable by geneva wheel mechanism according to the invention, although the drill rods illustrated provide particular advantages. A different structure of the mast may be used. Different means for applying power to the drilling head may be used, although the means of the invention for directly applying mechanical power to the drilling head for rotating the drill rods during drilling is particularly advantageous because it prevents slippage of the power means or stalling of the drill rods as can occur when a fluid powered drilling head is used and higher drilling resistance is encountered, which slippage or stalling impairs the drilling operation. Modifications may be also made in the mobile vehicle. Features of the invention such as the rack structure can be used in connection with other types of drilling apparatus than mobile drilling apparatus.
Other modifications than those indicated above may be made.
While the invention has been shown and described with respect to specific embodiments thereof, this is intended for the purpose of illustration rather than limitation; and other variations and modifications of the specific devices and methods of operation herein shown and described will be apparent to those skilled in the art, all within the intended spirit and scope of the invention. Accordingly, the patent is not to be limited to the specific devices or methods of operation herein disclosed nor in any way that is inconsistent with the extent to which the progress of the art has been advanced by the invention. | Disclosed is apparatus for drilling or boring a hole in the earth, as for forming blast holes. The apparatus disclosed is of the self-propelled mobile type having at one end a driver cab and at the other end drilling apparatus including a drill storage and handling rack adapted to store drill rods and as required to bring them into alignment with the drilling axis to form a drill string and to remove the drill rods from the drill string. The apparatus also supplies air to and through the drill string to blow out debris from the drilled hole. The apparatus includes a unique and efficient type of mechanism for rotating the drill rack to bring drill rods to or remove them from the drill string. Also disclosed is a unique type of drill rod particularly adaptable for use in the apparatus. | 4 |
FIELD OF THE INVENTION
The present invention relates to a ramp for a windsurfing raft which enables windsurfers to launch themselves into an abovewater launch trajectory so as to perform aerial stunt maneuvers.
BACKGROUND OF THE INVENTION
Up until now, aerial maneuvers by windsurfing craft have only been possible when a proper combination of waves and wind of suitable size and velocity has been present. Many substantially flat bodies of water, such as lakes and rivers, are exposed to sufficient winds desirable for the windsurfing sport but usually lack the inclined surface provided by waves for the aerial launching of a sailor and his windsurfing craft.
Previous attempts have been made to produce an inclined surface which would allow windsurfers to execute aerial stunt maneuvers. German patent application no. 35 24 494 discloses a jumping ramp for windsurfing craft that do not have a keel or rudder. The ramp is a continuous surface and is not provided with any means to accommodate the bottom rudder of a windsurfing craft having a rudder or keel.
U.S. Pat. No. 4,662,781 discloses an inclined ramp having a surface comprising upstanding bristles which alone cannot accommodate the rudder of a windsurfing craft. In order to allow the fin of a windsurfing craft to pass over the ramp, a complex arrangement of water jets is used in conjunction with a powerful pump to create a continuous mound or ramp of water. The system is complicated, expensive and not easily transported.
One attempt to provide a windsurfing ramp with means to accommodate the rudder of a windsurf board is shown in French publication no. 2,551,665. This ramp shows a number of complex parallel rails having a plurality of vertical balls or rollers mounted on the surface thereof. The structure is rigid and complex as well as being costly to manufacture. The rails 1a are constituted of metallic sections or in hard plastic having a square, rectangular or U-shaped cross section. The ramp has a very small launching surface and vertical guide rollers which are designed to accommodate very thick crafts. Also, when using a windsurf craft having a rudder, any slight deviation from a completely flat take-off could lead to disaster as the rudder may catch on any of the rigid vertical support members 2.
The French patent, like U.S. Patent No. 4,662,781, discloses a rigid ramp which offers little or no flexibility under the weight of a windsurfing craft and its sailor.
A need therefore exists for a windsurf ramp which is safe, easy to manufacture and transport, cost effective, and able to provide substantial lift to a surf craft rider for spectacular aerial stunt maneuvers.
SUMMARY OF THE INVENTION
The present invention overcomes the problems of the prior art by providing a windsurfing ramp which is flexible so as to provide a spring-type action and optimize the translation of windsurf craft velocity into launch trajectory. The present invention also provides a windsurfing ramp which is compact by design, may be easily transported and is easily assembled and installed. The present invention also provides a safe windsurfing ramp which negates the possibility of a windsurf craft rudder catching on a portion of the ramp and causing injury to a sailor and damage to the windsurf craft.
The present invention achieves the foregoing by providing a ramp which comprises a plurality of substantially parallel, spaced apart tubular members which are flexible under the weight of a windsurf craft and sailor. The support members are arranged in a planar configuration such that two ends of the configuration are defined by adjacent end portions of the support members. One end of the ramp which is defined by a set of adjacent end portions is submerged in a body of water while the other end, defined by the opposite end portions of the support members, is elevated in the water. Vertical support posts are used to support the elevated end above the surface of a body of water. Guide members are provided between the vertical support posts and the support members such that the rudder of a surf craft will not catch on the vertical support posts as a windsurf craft is projected off the elevated end of the ramp.
The present invention is easy to manufacture and can be set up and dismantled quickly without the need for a variety of tools.
BRIEF DESCRIPTION OF THE DRAWINGS
The above and other objects of the present invention may be better understood with reference to the accompanying drawings in which:
FIG. 1a is a side view of a jump ramp according to the present invention;
FIG. 1b is an enlarged view of a portion of the ramp in FIG. 1a showing details of the fin guard;
FIG. 1c is a side view of an embodiment of a ramp according to the present invention;
FIG. 1d is a perspective view of a portion of the embodiment in FIG. 1c showing a partial cut-away;
FIG. 2a is a top view of the elevated end portion of a ramp according to the present invention showing the support members in phantom;
FIG. 2b is a top view of a ramp in accordance with an embodiment of the present invention;
FIG. 2c is a front view of a portion of the ramp in FIG. 2b showing a two-crossbar arrangement and details of a side support member according to an embodiment of the present invention;
FIG. 3 is an end view of the submerged end portion of a ramp according to the present invention;
FIG. 4 is an end view of the elevated portion of a ramp according to the present invention;
FIG. 5a-5c are successive views of the invention in use;
FIG. 6a is a detailed view of the twist lock feature of the vertical support post and the retention slot for the fin guard;
FIG. 6b is a detailed view of the fin guard apparatus of the present invention in place;
FIG. 7a is a top view of a portion of an alternative embodiment according to the present invention showing roller means;
FIG. 7b is a partial cutaway view of a roller means shown in FIG. 7a;
FIGS. 8a and 8b are an end view and top view, respectively, of an automotive transport rack for a ramp according to the present invention;
FIG. 9 is an end view of a ramp without a fin guard, showing a possible point of contact with a windsurf craft rudder;
FIG. 10 is a top view of another embodiment according to the present invention;
FIG. 11 is a top view of another embodiment according to the present invention; and
FIG. 12 is a side view of another embodiment according to the present invention disposed on a surface of a body of water.
DESCRIPTION OF THE INVENTION
While the same reference numerals are used to depict similar parts of different embodiments of the present invention, it is to be understood that slight variations of each part can be made as exemplified by the different embodiments shown in the Figures. Components sharing the same reference numeral serve similar purposes.
The present invention relates to a ramp for a windsurfing craft comprising a plurality of substantially parallel flexible support members of substantially equal length spaced apart from each other at a distance. Means are provided to maintain the support members spaced apart. Each support member has a first end and a second end. The support members are arranged in a substantially planar configuration having a first end defined by adjacent first end portions of the support members and an opposite, second end defined by opposite adjacent second end portions of the support members. The substantially planar configuration of the ramp is also defined by first and second side edges opposite from one another and comprised of the two outermost support members.
The first end of the ramp is provided with means to force the first end below a surface of a body of water to define a submerged end when the ramp is disposed within a body of water. The second end, opposite the first end, is provided with means to force the second end above the surface of the body of water to define a elevated end when the ramp is disposed within the body of water. The distance between the support members is larger than a width of a rudder of a windsurfing craft and smaller than the width of a windsurfing craft.
Referring to the drawings, a ramp according to the present invention is supported upon a body of water 25 by a flotation means 1, which may be any number of well-known means used to float boating slips or the like. Floats may be used such as buoyancy billets, foam blocks, inflatable plastic chambers or other suitable means of floating the ramp. The ends of flotation device 1 normally extend four or more feet on both sides of the ramp device for stabilizing the ramp in rough water conditions.
A support platform 2 is secured by conventional means, e.g., nautical clips (not shown), or like means atop the flotation device 1. The platform is constructed of structurally-sound waterproof materials such as reinforced fiberglass materials, thermoplastics, nautical wood or the like. In the embodiment shown in FIG. 1a, 1c and 1d, the platform includes side support members 2a and at least one crossbar 2b. The crossbar 2b attaches to side support members 2a by means of wing-nuts and bolts, spring clips or other suitable means of securely assembling the platform 2. Preferably at least two crossbars are employed.
The embodiments shown in FIG. 1a, 1c and 1d employ two crossbars 2b, only the top one of which can be seen in FIGS. 2a and 2b. Two crossbars can be seen in the ramp shown in FIG. 2c. The crossbars 2b are provided with apertures 3 which are preferably spaced equidistantly eight to twelve inches apart along the lengths of the crossbars 2b. The apertures 3 are provided for the introduction of several vertical support members or posts 4, which may be fabricated of PVC pipe, anodized aluminum or the like. As seen in FIGS. 1d and 2c, the apertures 3 upon the upper crossbar are notched through their circumferences at notch 3a as shown to accommodate retention pins 45. The retention pins 45 are installed proximal to the bottommost rim of each post 4 as shown, such that each pin rests securely on the upper surface of the bottommost crossbar when the vertical support posts 4 are installed. The pins are preferably made of stainless steel, plastic or the like. A 2" to 3" length of each post 4 is inserted into a respective unnotched aperture 3b on the bottom crossbar. The stability, vertical alignment and security of each vertical support post 4 is ensured in this fashion. A retention bar 6 may then be inserted through apertures 104 of each member 4, as shown, and secured through side support members 2a by means of nautical bolts, wing nuts or the like for additional structural integrity. The retention bar is fabricated of any number of suitable, water-resistant materials. The embodiment shown in FIG. 1a uses two retention bars 6 to hold the vertical support posts in alignment.
Although the construction of vertical support posts 4 may be of a one-piece nature, the posts may also be made telescopic in nature by implementing a dual-pipe construction, for instance, a smaller diameter pipe inserted into a larger diameter pipe as shown in FIGS. 1a and 1b. A lock pin device 107, as shown in FIG. 4, or similar means may in turn be employed for locking the telescopic sections at the desired height setting. A multiplicity of matching apertures 108 within the sections of vertical support members 4 may be provided for varying the heights of the posts. As will become apparent, this embodiment facilitates ideal ramp surface conditions for advanced windsurfing stunts which require a specific pitch and/or yaw angularization upon launch, i.e., a staggered height of two or more vertical support members 4 can be provided. Such an arrangement is ideal for performing "barrel roll" and looping-type maneuvers as are known to be executed by sailors upon ocean-borne wave inclines. Of course, members 4 may remain of a standard height, with such an arrangement producing a ramp surface which would be ideal for novice and intermediate sailors to launch aerially therefrom.
Those skilled in the art will recognize that the addition of such measures as spring-load shock absorbers, oval- or square-shaped piping or like alterations to vertical support members 4 may, of course, be added and/or substituted without departing from the scope of the invention.
Ramp members or support members 7, which are preferably made of a semi-flexible piping such as PVC, thermoplastics of the like (said piping normally being at least three inches in diameter), are affixed to the tops of their respective vertical support posts 4 by means of apertures 3 disposed within the underside of each support member 7 and proximal to the end of same. Hollow plastic piping is particularly preferred. Notches may be provided for the insertion of additional retention pins 5, which may be installed proximal to the upper end of and through the upper circumference of vertical support posts 4. The vertical support posts 4 may then "twistlock" into position and thereafter the telescoping component may be secured at a desired height. It is by such means that the elevating, uniform support and equidistant spacing of the support members 7 is achieved. Of course, alternate means may be employed to secure support members 7 to their respective support posts 4. These alternate means include, but are not limited to, nautical hinge clips, universal joints and spring clip assemblies.
The support members 7 may alternatively comprise inflatable structures, flat floatable sections, reinforced rubber hose, plastic sheeting or the like as long as a flexible ramp surface is provided. Although support members 7 are preferably of a one-piece construction, normally between 10 and 15 feet in length, a sectional assembly may be used in order to compact the members. If sectional members are used, the means for connecting the sections must not mar, indent or otherwise compromise the integrity of windsurf crafts or the safety of a sailor as they travel over the ramp. The support members 7 are preferably sealed in a watertight fashion by means of foam plugs 13 or the like, with the air chamber formed therein providing an additional flotation component. The ends of support members 7 are also preferably beveled for safety purposes.
The submersible end of the ramp is provided with means to force the end below the surface of a body of water when disposed on the body of water. Means are also provided at the submersible end to space the support members apart from one another. As seen in FIG. 3, the submerged ends of support members 7 are spaced equidistant 8 to 12 inches, optimally, by means of spacer elements 9. The spacer elements may be made of any number of materials, such as hollow PVC piping, as shown, stainless lock-nuts or other appropriate means. A retention bar 106 is then inserted through apertures 111 disposed through, and proximal to, the ends of support members 7 and through spacer elements 9 placed between the support members. Spacer elements 9 may be affixed between ramp members 7 by means of nautical bolts or the like, the bolts being firmly secured on either side of the support members 7 and being tightened upon retention bar 106, as shown.
An excess of two or more feet of retention bar 106 at the end of the support members is exposed on both side edges of the ramp for the placement of front flotation buoys 10. The buoys 10 may be of any number of materials, shapes or sizes normal to such devices, provided their flotation capability provides ample support for the ramp while in use and does not block a windsurfing craft from sailing onto the ramp. Buoys 10 are affixed by bolts or other suitable means to buoy armatures 11 as shown in FIGS. 1a 3 and 5a-5c. The armatures are fabricated of piping, reinforced plastic, stainless alloys or the like. Additionally, armatures 11 may have a multiplicity of attachment apertures 111a spaced equally along both armatures 11 for their placement by bolts, clips or other suitable means upon the extended ends of retention bar 106. This embodiment allows for variable ramp angularization in relation to the horizontally disposed body of water 25. The shallowest setting 40 should normally be no less than two feet to allow for the safe clearance of a surf craft rudder device 50 as the windsurfing craft sails over the ramp entrance. The variable setting of the heights of buoys 10 and their armatures 11, in relation to retention bar 106 as seen in FIG. 1a will, when the telescopic nature of vertical support post 4 is taken into account, allow for a multiplicity of angular/height combinations of the ramp device.
Reinforcing support devices 12 are affixed by well-known means to both ends of retention bars 106 and cleated or otherwise secured to side support members 2a as shown. The support devices are preferably made of nautical rope, spring coils, guide wires, elastomeric members or the like. Support devices 12 are employed in this fashion to ensure that the ramp device will not collapse as a windsurfing craft sails up and off the ramp. The devices 12 may also serve to some extent as a shock-absorption measure. Of course, more than the two support devices 12 depicted may be utilized as deemed necessary for specific wind conditions or like consideration, i.e., device 12 may be positioned in tandem, criss-cross or other manner as deemed necessary for unusual sailing conditions and extremely heavy crafts and sailors.
In another embodiment of the present invention, rudderdeflecting cross members, herein referred to as fin guards 14, are provided on a windsurfing ramp, preferably as shown, to ensure the safe clearance of a windsurf craft rudder or keel. The fin guards may be constructed of rigid and smooth thermoplastics, reinforced fiberglass or similar high-strength, low-resistance materials which will give minimal friction or hindrance to the rudder upon encounter. Retention pins 15 of stainless steel or the like are installed through the ends of the fin guards which connect to the support members secured thereto as shown best in FIG. 6b. As seen in FIGS. 6a and 6b, the fin guard 14 may be inserted into a fin guard aperture 16 on a corresponding support member 7. The fin guard is biased toward aperture 3 on the vertical support post 4 to secure the fin guard 14 on its respective support member. The retention pin 15 serves not only to hold the fin guard 14 in position but also as a pivot point for the guard as it is moved by both body of water 25 and sailing actions upon the ramp. As seen in FIGS. 4 and 6b, the trailing end of fin guard 14 may now be securely cradled around the circumference of its individual vertical support post 4.
The guard 14 possesses a curvature which gives the guard a snug fit around post 4. The deflective foil thus created ensures the rudder on a windsurf craft to exit the ramp safely upon launch with minimal possibility of collision, as depicted in FIG. 9, of the rudder with vertical support post 4 or other components of the ramp. Additionally, retention pins (not shown) may be implanted through the back of guard 14 and through post 4 for additional stability as needed. It will be recognized by those skilled in the art that the dimensions, shape and materials used in the fabrication of fin guards 14 may vary provided the length and maximum stress loads of rudders normally installed upon windsurf craft are taken into consideration, thereby ensuring successful rudder deflection and the resultant safety of the sailor and protection of the craft.
Although the smooth surfaces of support members 7 have been found optimal in allowing windsurf craft to traverse thereupon with minimal friction, the normally hard surfaces of support members 7 may possibly, after prolonged ramp usage, scratch, mar or otherwise affect the bottom hull surface of windsurf craft. A resilient padding, such as 2" polyethylene, closed-cell, high-density rubber or the like, has been found to be successful in counteracting this action. However, such padding normally does not possess the necessary slippery, low-resistance texture as has been found preferable for optimum use by windsurf craft and as is provided by preferred support members.
In one preferred embodiment as seen in FIGS. 7a and 7b, rotational hubs 17 may be used in conjunction with padding 18 to provide a ramp surface which not only has low-friction but also gently cushions the bottom of windsurf craft as it ascends the support members 7. Optimally, the hubs are spaced two to four feet apart along support members 7. The padding hubs 17 are preferably made of a resilient material such as thermoplastic materials, or of stainless steel or other rust-resistant, high-load capacity materials and, as seen in FIG. 7b, are preferably of a diameter and width which not only supports a windsurf craft but also allows for free rotation within the support member through individual wheel wells 19. The subsequent flexation of support members 7 is also to be taken into account with regard to the nature and dimensions of padding hubs 17 and wheel wells 19 to avoid pinching the hubs or other hindrances to the rotation thereof.
An axle and bearing assembly 20, preferably being fabricated of similar materials as 17 and possessing adequate structural integrity for maximum anticipated stress loads, is provided through each padding hub 17 as shown. The axle and bearing assembly 20 is affixed by rivets (not shown), or other suitable means to the sidewalls of support members 7 for safety purposes. Padding 18, having a suitable thickness and generally the same width as 17, may be glued or otherwise affixed to respective padding hubs to form padded hubs. The padding is made of a resilient material to cushion and protect the windsurf craft. The padding 18 may be fabricated in a circular one-piece fashion similar to that of an automotive tire, so that not only is the initial installment expedient, but also, as the padding 18 wears down or otherwise becomes unusable, replacement is easily realized by simply refitting a new padding 18 on the hub 17.
Optimally, the hubs are recessed and concave along their outer rims, as shown, to positively retain padding 18 upon their surfaces. As may be seen in FIGS. 7a and 7b, additional foam plugs 13 may be installed on both sides of wheel wells 19 so that the flotational integrity of support members 7 is preserved. Of course, the present invention remains operational without this embodiment, with the padding system described being primarily for the preservation of specially crafted models of windsurf craft. Many windsurfing boards have been known to cost several thousand dollars and their protection is of utmost concern to their owners and riders.
The ramp of the present invention is optimally positioned perpendicular to wind direction in use and may be situated with the inclined surface allowing for either starboard or port tack aerial maneuvers, e.g., the ramp may be facing toward or away from the shoreline as desired. Other ramp angles relative to wind direction are, of course, possible and may be implemented for enabling stunt maneuvers. A windsock 21 and post 22 may be installed as shown and have been found useful in accurate ramp positioning in relation to wind direction. The windsock 21 also serves as a wind strength indicator, with a limp windsock 21 showing approaching sailors that a jump should most likely not be attempted. The ramp is preferably positioned in an area upon a body of water of adequate depth, normally being at least six feet or more so as to cushion the sailor if he should be thrown from the windsurfing craft or otherwise have an unsuccessful jump attempt.
To assure proper placement and retention of the ramp upon the body of water, anchors 23 and nautical ropes 24 may be implemented as shown. The anchor ropes 24, which are affixed by well-known means such as nautical cleats or the like, may be adjusted in length and tautness with respect to such variables as specific mooring depth, tidal strength, rip current patterns and like factors. This is especially advantageous in properly submerging the ramp entrance area and, in conjunction with buoys 10, as seen in FIG. 5b, to keep the ramp from capsizing during normal use. These embodiments enable the windsurf craft 8 and its sailor to make a clean and safe transition from the horizontally disposed body of water 25 onto and over the ramp with minimum danger or disturbance to the windsurfing craft 8 or the individual sailor.
As seen in FIGS. 5a-5c, the windsurf craft 8 may slide upon support members 7 and up the ramp, with the rudder device on the craft tracking in between two of the support members. As it makes its way up support members 7, as seen in FIG. 5b, the combination of the weight of windsurf craft 8 and its sailor, and the velocity with which they encounter the ramp device, causes the flexible members 7 of the ramp surface to yield accordingly. This slight flexing of the ramp members 7 upon introduction of the windsurf craft 8 to the ramp serves not only to act as a shock absorbing measure for the sailor but also causes the ramp to assume a position of parabolic angularization similar to that of an actual wave crest. This is advantageous in that this angled flexation of members 7 subsequently forms an optimum arc of ascent, causing windsurf craft 8 to be launched into a trajectory comparable to that afforded by a natural ocean wave. The trajectory and ramp arc may, of course, be affected by the preset angle and height of either or both ends of the ramp. Also, the flexible support members 7 act as springs to propel the sailor and windsurf craft higher into the air than can be achieved with a non-flexible ramp.
As the sailor and his craft 8 depart aerially from the ramp device, fin guards 14 assure safe rudder clearance, allowing the sailor to be propelled into an aerial launch trajectory. The present invention may be constructed so as to be extended to great widths, allowing the windsurf ramp to accommodate a great number of sailors simultaneously.
According to alternative variations of the present invention, support members 7 may be bent or formed so as to provide a variety of jump surfaces. As can be seen in FIGS. 1a, 3, 10, 11 and 12, various modifications can be made to the support members.
As can be seen in FIGS. 1a and 3, the submerged ends of support members 7 can be bent downward for safety purposes. Alternatively, a safety fitting 35 can be attached at the submerged end of each support member. FIG. 3 only shows one safety fitting 35 as an example. The safety fitting ensures the safety of a sailor should the sailor be ejected from the craft or otherwise have a fall near the ramp entrance.
FIGS. 10, 11 and 12 show other modifications to the support members 7. The elevated ends of support members 7 may be bent in the shape of a plane or continuous curve. Extensions 60 shown in FIG. 10 and extensions 70 shown in FIG. 11 may be connected or integrally formed with support members 7 at their elevated ends to provide a jump surface which is well suited for performing windsurfing stunts encompassing arcing aerial maneuvers. Extensions 60 may curve in either or both directions perpendicular to the support members, as shown. Extensions 70 shown in FIG. 11 are further supported by the offset placement of additional ramp components, e.g. floats 1, supports 4, platform 2, etc. Difficult banking maneuvers are thus made possible.
FIG. 12 shows another embodiment wherein the support members are symmetrically bent along a vertical plane and supported in the middle. With additional submerged end components a bi-directional ramp configuration is enabled for dual tack aerial stunts.
As will be recognized by those skilled in the art, the invention in the aforementioned design may be easily disassembled and compacted for transport. Automotive racks 26 fabricated of steel, plastic or the like, have been found useful in transporting the larger components of the present invention, namely support members 7 and crossbars 2b, although additional ramp components and windsurf craft 8 may be added to the load of the rack 26 as desired. As seen in FIGS. 8a and 8b, rack members 27a and 27b are joined to each other via a hinge joint 28, allowing member 27b to swivel up and allow the insertion of several support members 7 within the apertures a' provided thereon. When 27a is fully loaded, rack members 27b may swivel down, with the matching apertures a' provided upon its bottom side securely enclosing the diameters of each support member 7. A pressure clip-lock 29 or similar device is employed for the mating of 27a and 27b and ensures the security of the members 7 therein during transport. Additional apertures a' are provided atop rack member 27b for securing thereto the remainder of support members 7, with additional apertures b' for the transport of crossbars 2b. Rack straps 30, being made of nylon webbing or the like, are used for securing these and possibly other elements atop rack member 27b, with each strap 30 in turn being cinched down tight via spring rachet devices (not shown), pinch clips or the like. As seen in FIG. 8b, each auto rack 30 may be positioned parallel atop automobile 31 and secured thereon via rain gutter clamps 32, which are widely known and used for similar purposes. Additionally, a padding 33 may be provided within apertures a' and b' for protection of the invention during transport. This system allows the sailor to easily transport the disassembled invention to his favorite lake or river, with the less bulky components normally being stored in the trunk and/or back of the automobile.
The invention is not limited to the specific embodiments described and illustrated herein. It will be appreciated that various modifications, substitutions, adaptations or combinations may be made without departing from the spirit and scope of the invention defined in the appended claims. | A windsurfing ramp which is flexible so as to provide a spring action and optimize the translation of windsurfing craft velocity into launch trajectory. The windsurfing ramp is compact by design, easily transported and easily assembled and installed. The windsurfing ramp is safe and eliminates the possibility of a windsurf craft rudder catching on a portion of the ramp thus injuring a sailor or damaging the windsurf craft. The ramp is made up of a plurality of substantially parallel, spaced apart tubular members which are flexible under the weight of a windsurf craft and sailor. The support members are arranged in a planar configuration such that one side edge is submerged when disposed on a body of water while an opposite side edge is elevated in the water. | 0 |
BACKGROUND OF THE INVENTION
This invention relates to a rolling mill having a grooved roll such as a bar or wire rolling mill in which the dimensions of a rolling material are controlled.
One example of the arrangement of a successive rolling mill of this type is shown in FIG. 1.
The successive rolling mill comprises i stands. In FIG. 1, reference numeral 1 designates a mill stand; 2, a #2 stand; 3, a #i-1 stand; 4, a #i stand; and 5, the rolling material. The successive rolling mill in FIG. 1 is a so-called VH type rolling mill. That is, horizontal rolling machines (the odd-numbered stands in FIG. 1) and vertical rolling machines (the even-numbered stands in FIG. 1) are alternately arranged.
For instance, the #i-1 stand rolling machine 3 is a vertical rolling machine which carries out rolling in the direction X. In FIG. 1, reference character bi-1 designates the lateral width of the rolled material at the output of the #i-1 rolling machine, and reference character hi-1 designates the height thereof. The #i rolling machine is a horizontal rolling machine which carries out rolling in the direction Y. Reference character bi designates the lateral width at the output thereof, and reference character hi designates the height.
In a conventional successive rolling mill such as a bar or wire rolling mill, in order to reduce tension of the material between the stands equal to zero, loop control or a tension control mechanism has been employed. However, a successive rolling mill in which the dimensions of the rolling material are dynamically controlled has yet to be provided in the art because of the following reasons:
(1) The tolerances on the dimensions of the products have not been severe, and
(2) Elongation of the mill due to a variation in the load during rolling is small. (This reduces the effect of transmitting a variation of a rolling material at the input side to the delivery or output side, and therefore the accuracy of product dimension is not greatly varied.)
Thus, the conventional control is disadvantageous in that the dimensional accuracy is low, because, for example, the dimensional variation due to variations in the temperature of the rolling material is not controlled at all.
SUMMARY OF THE INVENTION
This invention has been made in view of the foregoing drawbacks and it is an object thereof to perform rolling with high dimensional accuracy by forecasting the width deviation of the material from a reference dimension at the delivery side of i-th stand by detecting actual dimension of a given two (i-1)-th and i-th stands. And according to this duration screw position of (i-1)-th stand is controlled. Together with mentioned above, the width of the rolling material at the delivery side of the i-th stand is actually detected, and the screw position of the (i-1)-th stand is controlled so that the deviation between the width detected and a reference width at the delivery side of the i-th stand is reduced to zero, whereby the dimensional accuracy in successive rolling is improved.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is an explanatory diagram showing one example of the arrangement of a successive rolling mill;
FIG. 2 is a block diagram showing a dimension control device according to one embodiment of this invention; and
FIGS. 3a and 3b are characteristic diagrams indicating the relations between the height and width of a rolling material and the depression position of a rolling machine.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
In FIG. 2, reference numeral 3 designates a #i-1 rolling machine; 4, a #i stand; and 5, a rolling material. Depressing or screwing down motors are provided for the stands, and load cells 9 and 10 detect rolling loads. Depression or screw position detecting pulse oscillators 11 and 12 are coupled to the motors 7 and 8, and motor driving thyristor devices 13 and 14 supply electric power to the motors 7 and 8. At 15 and 16 are shown mill spring control devices for the stands.
A motor 20 is provided for driving the rolling roll of the #i-1 stand, and a motor 21 is disposed for driving the rolling roll of the #i stand. Thyristor devices 22, 23 drive respective motors 20 and 21. A loop control device 24 maintains a given amount of loop between the #i-1 stand the #i stand, and a width detecting device 25 is arranged for detecting the width of the material at the output side of the #i stand. A gain controller 26 multiplies a difference Δbi between the width bi detected by the width detecting device 25 and a reference width bi(REF) by a predetermined control gain; and the output of the gain controller 26 is feed to a screw position controller 27, control gain which is a PI(D) controller, and by this controller a screw position correction signal is fed to the screw down motor of the #i-1 stand.
Further in FIG. 2, reference numeral 28 designates a width detecting device for detecting the width of the rolling material at the delivery or output side of the #i-1 rolling machine; and a height detecting device 29 detects the height of the same. In a divider 30, the difference between a detection value bi-1 of the width detecting device 28 and a reference width bi-1(REF) in the #i-1 stand is divided by the reference width bi-1(REF), and in a divider 31, the difference between a detection value hi-1 of the height detecting device 29 and a reference height hi-1(REF) for the #i-1 stand is divided by the reference height hi-1(REF).
A forecasting device 32 receives the output of the divider 30, for forecasting the change which will be caused in the width at the delivery side of the #i stand 4 by a change in the width at the delivery side of the #i-1 stand 3. Simultaneously, a forecasting device 33 receives the output of he divider 31, for forecasting a change which will be caused in the width at the delivery side of the #i stand 4 by a change in the height at the delivery side of the #i-1 stand. In a gain controller 34, the composite output of the forecasting devices 32 and 33 is multiplied by a predetermined control gain; and in a screw position controller 35, which is a PI(D) controller, and by this controller a screw position correcting signal is fed to the screw down motor of the #i-1 stand.
In most conventional systems, the loop control device 24 controls the speed of the motor 20 of the i-1 stand whose set speed was Ni-1 (REF) so that the amount of loop between the #i-1 stand 3 and the #i stand 4 is made constant. However, according to this system mentioned above only, the dimensions of the products are solely determined by the characteristics of the rolling machine, and therefore it is impossible to dynamically control the dimensions. A mill spring control method (BISRA control) is known in the art, in which, with the aid of the loads detected by the load cells 9 and 10, the mill spring controllers 15 and 16 detect variations in height, to control the screw positions. However, as it is impossible for the method to control dimensions in both directions (i.e. both width and height), the overall dimensions are poor in accuracy.
The operation of the control device according to the invention will now be described.
The width bi-1 and height hi-1 of the rolling material 5 are detected by the width detecting device 28 and the height detecting device 29 arranged on the delivery side of the #i-1 rolling machine 3. The difference Δhi-1 between the height hi-1 thus detected and the reference height hi-1 (REF) of the #i-1 stand is fed to the divider 31.
Similarly, the difference between the detected width bi-1 and the reference width bi-1(REF) is fed to the divider 30.
In the control device according to the invention, using the height deviation Δhi-1 and width deviation Δbi-1 detected at the delivery of the #i-1 stand, the width deviation Δbi at the delivery of the #i stand 4 is calculated, to eliminate width deviation Δbi at the delivery of the #i stand by feedback control.
In order to eliminate the width deviation at the delivery of the i-th machine 4, it is necessary to control the position of the stand 3, as described in detail below.
FIG. 3a indicates height (hi) deviations and width (bi) deviations caused when the screw position Si of the #i stand rolling machine is deviated. FIG. 3b indicates height (hi-1) and width (bi-1) deviations, and also height (hi) and width (bi) deviations at the delivery of the respective i-1th and i-th rolling machines caused when the screw position Si-1 of the #i-1 stand rolling machine is deviated.
A method of correcting the position Si of the #i rolling machine 4 and that Si-1 of the #i-1 rolling machine 3 are available in controlling the width bi at the delivery of the #i stand rolling machine, as is apparent from FIGS. 3a and 3b. When the screw position Si of te #i stand rolling machine is corrected, not only is the width bi, but also the height hi is changed. On the other hand, when the screw position Si-1 of the #i-1 stand rolling machine 3 is corrected, the height hi at the output of the i-th stand is scarcely changed. In the invention, based on this fact, the width deviation Δbi at the delivery of the #i stand is compensated by controlling the screw position of the #i-1 stand rolling machine 3. More specifically, according to the invention, the width deviation Δbi-1 and height deviation Δhi-1 at the delivery of the #i-1 stand rolling machine 3 are applied to the dividers 30 and 31, respectively, where they are divided by the reference width bi-1(REF) and reference height hi-1(REF) at the delivery of the #i-1 stand.
The output (hi-1(REF)-hi-1/hi-1(REF)) of the divider 31 represents a height deviation factor at the delivery of the #i-1 rolling machine 3, and the output (bi-1(REF)-bi-1/bi-1(REF)) of the divider 30 represents a width deviation factor at the delivery of the #i-1 stand.
The output of the divider 30 is applied to the forecasting device 32, while the output of the divider 31 is applied to the forecasting device 33.
The forecasting device 32 forecasts the width deviation at the delivery side of the #i stand using a coefficient representing the influence that the width deviation factor at the delivery of the #i-1 stand rolling machine 3 has on the width deviation at the delivery side of the #i rolling machine. On the other hand, the forecasting device 33 forecasts the width deviation at the delivery of the #i stand 4 using a coefficient representing the influence that the height deviation factor at the delivery of the #i-1 stand rolling machine 3 has on the width deviation at the delivery of the #i stand.
The outputs of the forecasting devices 32 and 33 take values which are determined from the characteristics of the rolling machines and the properties of the rolling material, and which can be calculated in advance. Accordingly, by combining the outputs of the forecasting devices 32 and 33, the forecast width deviation Δbi* at the delivery of the #i stand due to the height and width deviations at the delivery of the #i-1 rolling machine 3 can be obtained.
The forecast deviation Δbi* is applied to the gain controller 34. In the gain controller, in order to eliminate the forecast width deviation Δbi*, the composite output is multiplied by a predetermined gain for correcting the position of the #i-1 stand 3, to provide an output. The value of the control gain multiplier of the gain controller 34 can be calculated from the gradient of the bi deviation characteristic curve with Si-1 changed, in FIG. 3b.
The output of the gain controller 34 is applied to the screw position controller 35. In the controller 35, the output of the gain controller 34 is subjected to PI(D) control, and a screw position correction signal is applied to the depressing device including the screw down motor 7, the pulse oscillator 11 and the motor driving thyristor device 13.
The motor 7 is driven by the motor driving thyristor device 11 until the screw position detected by the pulse oscillator 11 coincides with the screw position correction signal.
By this control, the width deviation at the delivery of the #i stand due to a deviation in the dimension of the material at the delivery of the #i-1 stand is compensated.
In the above-described system, the dimensions of the material at the delivery of the #i-1 stand are detected to control the dimensions of the material at the delivery of the #i stand, and therefore the control is excellent in response; however, the dimensional accuracy is not always sufficient.
In the invention, therefore, in order to obtain more satisfactory dimensional accuracy, the width detector 25 is provided at the delivery of the #i stand rolling machine 4, so that feedback control is carried out with actually measured values.
That is, the width is detected by the width detector 25 provided at the delivery of the #i stand rolling machine 4, and the difference Δbi between the width thus detected and the reference width bi(REF) at the delivery of the #i stand is applied to a gain controller 26. The gain controller 26 is similar in arrangement to the gain controller 34. The output of the gain controller 26 is supplied to a screw position control device 27, where the output of the gain controller 26 is subjected to PI(D) control, and similarly as in the case of the screw position control device 35, a screw position correction signal is applied to the screw device of the #i-1 stand.
In the above-described embodiment, the height detecting device 29 actually measures the dimension of the rolling material 5 at the delivery of the #i-1 stand; however, the dimension may be detected by other means, i.e. by calculating from the screw position Si-1 of the #i-1 stand, the mill spring constants and the rolling load.
Furthermore in the above-described embodiment, the height and width of the material at the delivery of the #i-1 stand are detected, so that the width deviation of the material at the delivery of the #i stand can be forecast from the percentages of deviation in the height and width thus detected. However, the width deviation of the material may be forecast by detecting only one of the height and width. Moreover, the forecast may be achieved by detecting the height and width of the material at a point upstream of the #i-1 stand instead of at the delivery of the #i-1 stand.
As is apparent from the above description, according to the invention, the deviation in the dimension of the material between any two stands is utilized to forecast the width deviation of the material at the delivery of the #i stand located downstream, and the screw position of the #i-1 stand rolling machine is controlled so that the width deviation thus forecast is reduced to zero; and the width of the material at the delivery of the #i stand rolling machine is actually measured, and the screw position of the #i-1 stand is controlled so that the difference between the width thus measured and the reference width of the material at the delivery of the stand is reduced to zero. Therefore, the controller of the invention is excellent in response and can perform rolling control with high accuracy. | A rolling mill control device detects a dimension or dimensions of a product material between two mill stands, and forecasts a width deviation value of the material at a downstream stand on the basis of rolling characteristics of the material, etc. The position of an upstream stand is then varied to reduce the forecast value to zero. Feedback control is also effected on the position of the upstream stand based upon the difference between a reference width and an actually measured value. | 1 |
This invention relates to a lawnmower reel-to-bedknife adjustment system, and, more particularly, it relates to an adjustment system whereby a specified clearance between the reel and bedknife can readily be achieved
BACKGROUND OF THE INVENTION
Adjustable bedknives for reel-type lawnmowers are commonly known. It is the purpose of those mowers to have a slight clearance between the rotating cutting reel and the bedknife. The bedknife is commonly movable toward and away from the reel to present a cutting edge against which the reel rotates and thereby operates to cut the grass. The prior art is already aware of various adjustments for adjusting the bedknife relative to the reel and thus establish the desired clearance for optimum cutting. Examples of the prior art are found in U.S. Pat. Nos. 3,187,492 and 3,680,293 and 4,335,569 and 4,345,419. The first three of said patents show pivotally mounted bedknives controlled by threaded members to thereby be positioned with their cutting edges relative to the rotating reel. The last said patent shows a fixed bedknife with a movable reel and with a piston type of fluid dampener controlling the reel.
The present invention differs from the prior art in that it provides for a bedknife-to-reel adjustment system whereby the bedknife cutting edge can always be positioned at a desired specified small tolerance or clearance relative to the cutting edge of the reel itself. That is, the bedknife can be adjustably moved into actual contact with the reel cutting edge, and then there is an automatic further movement of the bedknife to attain the desired small clearance of the bedknife cutting edge with respect to the cutting edges of the reel, as desired. The small clearance is automatically attained by virtue of the mechanics of the adjustment system itself, and it need not be manually achieved, and it is therefore consistent and accurate. Still further, the small clearance can be controlled and set at determined magnitudes, and then it is again automatically attained according to the setting.
The present invention provides for an on-the-job adjustment or setting, in accordance with the desires of the operator. Also, the entire system is capable of releasing the bedknife when debris, such as sticks and stones, become lodged between the bedknife and the reel, and thereby avoid dulling or any damage to the cutting edges.
An important aspect of this invention is the provision of the adjustment system mentioned and whereby the adjustment is automatically achieved in a very small or minute dimension, such as 0.001 to 0.003 inches, to thus provide for the optimum adjustment and avoid excessive wear between the respective cutting edges and to yet assure that the grass will be well mowed.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is side elevational view of a preferred embodiment of this invention.
FIG. 2 is an enlarged side-elevational view of a fragment of FIG. 1.
FIG. 3 is an enlarged side-elevational view of a slightly different embodiment from that shown in FIG. 1, but showing a fragment thereof, and likewise for FIG. 4.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
The invention pertains to a conventional type of reel lawn mower having a wheel 10 and a ground engaging roller 11, both of which ride on the ground designated by the line G. A conventional type of cutting reel is designated at 12 and shown in its circumference in dot-dash lines, and it would present a cutting edge at the circumference 13, in a conventional manner. A mower frame 14 is shown in dot-dash lines and rotatably supports the wheel 10 and the reel 12 and the roller 11, all in the conventional arrangement which will be well understood by anyone skilled in the art.
A bedknife, generally designated 16, is pivotally mounted on the frame 14 on a pivot axle 17. The bedknife 16 has an elongated upstanding portion 18 and a shorter and generally horizontally extending portion 19. A bedknife cutting surface or edge 21 is shown adjacent the reel circumference 13, and there is a slight dimensional clearance designated C between the reel 12 and the cutting edge 21 of the bedknife 16. The reel 12 is on a fixed axle 22, but the bedknife 16 will pivot about its pivot mounting 17 so that the bedknife cutting edge 21 can move toward and away from the reel circumference 13 for establishing the clearance C relative to the reel 12. Of course the cutting edge 21 extends across the width of the mower, as does the reel 12 also, all in the conventional arrangement.
Therefore, movement of the bedknife upper end 23 in the left and right direction, as viewed in FIG. 1, will pivot the bedknife 16 about its pivot member 17 to thus move the cutting edge 21 toward and away from the reel cutting edge or circumference 13. It will be further noted that the dimension between the pivot member 17 and the bedknife cutting edge 21 is substantially less than the dimension between the pivot member 17 and a pivot connecting member 24 at the bedknife upper end 23. Thus, only slight movement of the pivot connector 24 will induce even less movement of the bedknife cutting edge 21, and thus very fine adjustment of the cutting edge 21 relative to the reel circumference 13 can be achieved, as desired. As shown, the difference in the aforementioned dimensions from the pivot member 17 are approximately in a ratio of one to two. Thus, one increment of movement of the connector 24 will induce approximately only one-half of that movement at the cutting edge 21 to create the fine adjustment desired.
A link or connector 26 is shown pivotally connected with the connective member 24, at one end of the link 26, and the other end of the link 26 is pivotally connected with a pivot connector 27 on the frame 14. Thus, the link 26 is articularly connected at its opposite ends between the bedknife 16 and the mower frame 14. Further, the link 26 is in two parts 28 and 29 which can move toward and away from each other to create an extension and retraction of the overall length of the link 26 and thus induce the pivot movement of the bedknife 16, as mentioned. Also, the link part 29 includes a rod 31 and a piston member 32, with the parts 31 and 32 being threaded together, at 33, and thus being further extendable and retractable by means of the screw threads 33 to provide for a manual adjustment of the overall length of the part 29.
FIG. 2 shows the part 32 is slidable in a piston chamber 35 in the part 28, to thus form a piston and cylinder arrangement between the parts 32 and 28. A fluid inlet opening 34 extends into the part 28 and to the chamber 35 to permit fluid under pressure to reach the end wall 36 of the piston member 32 and thus move the piston member 32 to the right, relative to the part 28, and thereby increase the length of the link 26 between its articular mountings 27 and 24.
The part 28 also carries a collet-type screw member 37 which is threaded into the member 28 and clamps upon a rod 38 extending therethrough and which is connected to an end plate 39 within a chamber 41 in the part 32. Thus, in a conventional collet arrangement, the rod 38 can be yieldingly held by the screw-type collet member 37 to thus yieldingly position the end plate 39. A cylindrical member 42 is freely disposed in the chamber 41 which also contains a compression spring 43 which abutts the end plate 39 and another plate 44, as shown. With that arrangement, when fluid is applied to the piston part 32, including against the surface 36, the piston 32 moves to the right and likewise displaces the end plate 44 and the spacer sleeve 42 to contact the end plate 39 and possibly move it to the right also, depending upon dimensional settings. Any movement of the plate 39 would be permitted by the rod 38 sliding in the friction-tight holding, but yieldable holding, of the collet 37. That condition might be as then shown in FIG. 3. Next, upon release of the fluid pressure, the spring 43 will be based upon the end plate 39 and will force upon the end plate 44 to return the piston 32 to the left, and the piston part 32 is then moved against the end plate or stop 39, as shown in FIG. 2. The dimensional relationships of those parts are such that the clearance C is then developed between the reel 13 and the bedknife cutting edge 21. The actual arrangement of the assembly, as shown in FIG. 2 is that which is already utilized in vehicle brake assemblies.
FIG. 3 also shows that arrangement for the link 26, and it too would operate with a fluid pressure entering at an inlet 46 in the member 28, and again the collet rod 38 is attached with the end plate or stop now designated 47, as described in FIG. 2. In both instances, the cylindrical spacer tube 42 determines the amount that the end plates 39 and 47 will travel, if they travel at all, when fluid pressure is applied, and thus dimension tolerance, wear, and the like are accomodated and the same desired clearance C is always established when the adjustment is made as described. FIG. 3 shows that the spacer tube 42 is already contacting the adjustable stop 47, and thus the link 26 would continue to extend until the bedknife cutting edge 21 contacts the reel circumference 13. Upon release of the fluid pressure, then the link 26 would contract, by having the spring 43 return the piston part 45 to the left, to establish the preset clearance C, as mentioned.
FIG. 3 also shows that the link part 29 has two threaded adjustments at 48 and 49, and these of course can be of opposite threading so that upon loosening the lock nuts 51, the double threaded rod 52 can be turned to extend or contract the overall length of the link 26 and thereby provide a manual adjustment for the setting of the cutting edge 21 in the context described herein.
It will be further seen and understood that when debris, such as stone, sticks, or the like become embedded between the reel 12 and the bedknife cutting edge 21, the assembly will permit adjustment by permitting pivoting of the bedknife 16 and contraction of the link 26 when the collet rod 38 overcomes the frictional force of the collet 37. Of course, the setting of the parts, prior to upset by the aforementioned debris, can be readily achieved by re-applying the fluid pressure and releasing same to establish the clearance C once again. Further, the tightening of the collet 37 can be achieved in order to permit the frictional holding of the rod 38, for the purposes mentioned and desired in this overall assembly.
Since the upstanding portion 18 of the bedknife 16 is of a substantially greater length than the bedknife portion from the pivot mounting 17 to the cutting edge 21, the clearance C can be minutely established since perhaps only half the displacement of the link 26 is reflected in the movement of the cutting edge 21, as previously mentioned. In actuality, a clearance of only 0.001 to 0.003 inches can be readily achieved by this arrangement, and that is desirable. The initial clearance C can be pre-set or shimmed at the assembly, to give the desired bedknife clearance within the context described herein. Also, since the resisting force created by the collet 37 must be sufficient to maintain the bedknife clearance against heavy cutting loads at the reel, but it must also allow movement when the cylinder is pressurized, again the large numerical ratio of the bedknife portion 18 to the portion 19 is an advantage.
It will be seen and understood that the drawings, particularly FIG. 3, also show that there is a part 45 which contains the spacer 42 and the spring 43, and it is threaded at 33 for adjusting the length of the link 26. Also, link 26 includes a part 50 which is threaded opposite at 55 and receives the part 52.
The embodiment of FIG. 4 shows the conventional mower reel shaft 56, and the reel itself is conventional and is indicated by the solid circle 57. The bedknife is generally designated 58, and it includes the cutting edge 59 which is adjacent the reel 57 and is shown to have a clearance therewith and designated 61, and that can be the desired mowing clearance. The bedknife 58 is suitably and pivotally mounted on the mower conventional frame by means of a pivot pin 62, for instance. The bedknife 58 includes the generally horizontally extending portion 63 and the generally upright or vertically extending portion 64. It will also be noticed that the portion 63 is indicated to have a smaller dimension from the pivot pin 62 to the cutting edge 59, and designated 66, compared to the larger dimension from the pivot pin 62 and to the upper portion of the bedknife 58 where there is a control member designated 67, and that larger dimension is designated 68. Just as in connection with the embodiment of FIG. 1, with the larger dimension 68, a movement of the bedknife upper portion 69 will create a smaller movement of the cutting edge 59, and thus the fine or small adjustment of the clearance 61 is attainable, as desired.
A fluid cylinder assembly 71 is mounted on the mower frame portion 72 and is attached at 73 to the bedknife 58. It will therefore be seen and understood by anyone skilled in the art that extension and retraction of the fluid assembly rod 74 will cause the bedknife 58 to pivot about its mounting pin 62. Of course the operator will have control over the assembly 71 to induce the bedknife pivot action mentioned. Also, a relatively heavy spring 76 extends between the bedknife portion 63 and the mower frame 77 to bear downwardly on the portion 63 and thereby induce counterclockwise rotation of the bedknife 58 about the pin 62, as viewed in FIG. 4.
The link or connector generally designated 67 includes a rod 78 connected to the bedknife upper portion 69 by extending through a lug 79 affixed to the bedknife portion 69 and having an opening 81 for slidably receiving the rod 78. A collar 82 is on the end of the rod 78 and abutts the lug 79 on the right thereof, as viewed in FIG. 4. It will therefore be understood that when the bedknife 58 is pivoted clockwise, then the rod 78 will move to the right as the lug 79 moves against the collar 82.
The link or connector 67 is restricted in its movement leftward, as viewed in FIG. 4, by means of the one directional mechanism designated 83, and that being a conventional one-way mechanical lock such as shown in U.S. Pat. No. 3,874,480. In that instance, the rod 78 is free to move to the right, in a conventional manner for that mechanism 83, but, coil springs 84 on the rod 78 preclude easy movement of the rod 78 to the left and relative to the portion 83. That is, the rod 78 can slip to the right, but there is a resistance against its movement to the left since the coil springs 84 provide that leftward movement resistance. Of course the connector 67 is mounted on the mower frame portion 86 through the pivot pin 87 connecting to the mechanical lock 83, as shown.
With that arrangement, clockwise rotation of the bedknife 58 move the rod 78 to the right, and that movement continues until the cutting edge 59 abutts the reel 57, and that movement was induced by the extension of the fluid assembly 71, for instance. When pressure is released in the assembly 71, then the spring 76 will induce the counterclockwise rotation mentioned for the bedknife 58, and that will cause an adjustable stop 88 to have its surface 89 abutt the end 91 of the rod 78 which is now being held in its rightwardly fixed position, as mentioned. When the bedknife 58 has rotated counterclockwise to the position where the stop 88 abutts the rod 78, then the clearance 61, for instance, will have been established, as desired. It will of course be seen and understood that the stop 88 is adjustable in that it is threaded at 92 and is secured to the bedknife 58 by nuts 93. Therefore, an initial clearance designated 94 can be established between the rod end 91 and the stop surface 89, and that clearance would actually only exist when the cutting edge 59 is abutting the reel 57. Subsequently, as mentioned, the counterclockwise rotation of the bedknife 58 will cause the stop surface 89 to abutt the rod end 91 and thereby create the cutting clearance 61.
Of course different mechanisms could be employed for the one directional movement of the connector 67, such as the rightward movement of the rod 68 as described, and the mechanism 83 could therefore be replaced by these different and conventional mechanisms, such as a sprag which would operate on a rotational principle which anyone skilled in the art will readily understand. In any event, the concept is that the connector 67 will move in the one direction, to the right as viewed in FIG. 4, but resist direction in the opposite direction, and thus provide the positioning of the cutting edge 59 under the influence of the spring 76 when the stop 88 abutts the rod end 91, all as mentioned.
Further, just as with regard to the previous embodiment, if debris or the like comes between the cutting edge 59 and the reel 57, then the bedknife 58 can rotate counterclockwise and the rod 78 will actually be forced against the resisting springs 84 to permit that rotation and thereby avoid damage to the mower. Further, a fixed collar 96 on the rod 78 provides a base for a spring 97 which abutts a sliding collar 98 on the rod 78 to thereby maintain the rod 78 relative to the lug 79, as shown.
The invention also includes the method of establishing a clearance at a location remote from the cutting members cutting edges, and that clearance is then proportionately transferred to the location between the cutting edges, to establish the final clearance therebetween. Therefore, in FIGS. 1 through 3, the initial clearance is first established in the connections, including the link 26, by virtue of the distance that the member 32 moves relative to the member 28, in FIG. 2 and when fluid pressure is applied in the chamber 41. With fluid pressure applied, per FIG. 3, spacer 42 moves stop 47 to the right and until the cutting edges 13 and 21 are in contact. Release of fluid pressure permits spring 43 to move members 32 or 45 to the left, to the position of FIG. 2, in lost motion action. As seen in FIG. 2, that lost motion is the clearance shown between the plate 39 and the adjacent end of the cylindrical sleeve 42. Of course when there is that clearance at that remote location as shown in FIG. 2, and also as shown in FIG. 4 and designated 94, then the cutting edges 13 and 21 are spaced apart. Therefore, the remote or initial clearance is proportionately transferred to the location between the cutting edges, to thereby provide the clearance "C" in FIG. 1 and the clearance 61 in FIG. 4, both as the final and desired clearance. | A lawnmower reel-to-bedknife adjustment system wherein the bedknife cutting edge can be automatically positioned relative to the circumference of the cutting reel. An extendable and retractable link is connected to the pivotal bedknife at a numerical advantage relative to the pivot axis and thereby provide for a fine adjustment of clearance between the reel and the bedknife upon extension and contraction of the link. The link can be extended by fluid pressure, or the like, and it can be retracted by spring pressure, and a yielding force is arranged to establish the clearance to a pre-set condition each time. Also, a manual threaded adjustment is provided along the adjustment link so that manual adjustment can be accomplished when desired. | 0 |
CROSS-REFERENCE TO RELATED APPLICATIONS
This application is a Continuation of U.S. application Ser. No. 13/145,697 filed under 35 U.S.C. Section 371, currently pending, of International Patent Application No. PCT/IB2010/050223 filed on Jan. 18, 2010, claiming priority to Italian Patent Application No. MI2009A000061 filed Jan. 21, 2009, all of which are hereby incorporated by reference as if fully set forth herein.
TECHNICAL FIELD
The present invention relates to a piston for pressure die casting, in particular for, without being limited to, cold-chamber die casting processes.
BACKGROUND OF THE INVENTION
It is appropriate to specify beforehand that, although in the following description reference will be made for simplicity mainly to cold-chamber pressure die casting, this should not however be understood as a limiting factor, since the present invention is also applicable to, unless specifically incompatible with, other types of pressure die casting processes (e.g. hot-chamber die casting) for metallic or non-metallic materials.
The cold-chamber pressure die casting process has been known for a long time, and therefore it will not be described in detail below, with the exception of what is strictly needed in order to understand the invention. For further information, reference should be made to the numerous technical and scientific publications on this matter.
In this process, molten metal is poured into a container having a cylindrical inner cavity, in which the metal is pushed by a moving piston towards an axial outlet, thereby being injected into a die containing the mould of the part to be cast.
This type of process is mostly used for producing parts made of aluminium-based light alloys, but its field of application has been recently extended to magnesium as well; the temperatures involved may reach quite high values (over 400-500° C.), and therefore piston cooling is an important factor for the proper execution of the production process.
According to the current state of the art, in these applications the piston is cooled by a liquid which is delivered to the most thermally stressed region, i.e. the piston head, which comes directly in contact with the molten metal, and is then evacuated along an inverse path.
In particular, the liquid flows into an axial duct within the support on which the piston is mounted, leading to the piston head; the liquid is spread onto the inner wall of the piston head through radial channels provided at the support end.
The coolant flow is thus distributed in a sunburst pattern and is then collected into a circular channel encircling the piston support, from which it finally returns to the support's axial portion to be evacuated.
Some examples of pistons cooled in this manner are described in European patent application EP 423 413 published on Apr. 24, 1991 and in International patent application PCT/IT2007/000255 published on Oct. 18, 2007.
While from a general viewpoint the cooling systems known in the art are considered to be reliable because they have been tested for a long time, the higher temperatures nowadays involved in pressure die casting processes, as aforementioned, give rise to the need of improving the efficiency of the thermal exchange between the piston and the coolant.
As a matter of fact, casting magnesium and its alloys makes the piston become very hot: it follows that, in order to remove more heat, there is no other solution than to act upon the thermal exchange area lapped by the coolant, i.e. to increase the piston dimensions.
However, this is not always feasible, because it would also require changes to the container in which the piston slides, so that de facto this solution is not applicable to existing pressure die casting fixtures, which otherwise should be replaced, involving high costs.
The technical problem at the basis of the present invention is therefore to improve the above-described state of the art.
In other words, the problem is to provide a pressure die casting piston which is cooled with greater efficiency than possible through the prior art.
A piston having the same diameter as the existing ones can thus be manufactured which, all other conditions being equal (coolant flow rate, wall length, etc.), ensures better performance because it is cooled more effectively.
The idea which provides a solution to the above-mentioned technical problem is to let the coolant flow within the piston wall: in this manner, the heat is removed directly from within the latter, thus increasing the thermal exchange.
The better piston cooling allows to increase the number of die casting cycles while still keeping the piston temperature under preset values ensuring the proper operation of the machine.
As a result, the productivity of the die casting equipment is increased as well, with evident advantages from an industrial point of view.
The aforementioned technical problem is solved by a piston having the features set out in the appended claims.
Said features and the advantages thereof will become more apparent from the following description of an embodiment of the piston according to the invention referring to the annexed drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
To understand the present invention, it will now be described by way of example, with reference to the accompanying drawings in which:
FIGS. 1 and 2 are two exploded views from different angles of a piston and a piston support according to the present invention;
FIG. 3 shows the piston and the support of the preceding figures in the assembled condition;
FIG. 4 is a detailed view of the piston of the preceding figures, without the support;
FIG. 5 is a longitudinal sectional view of the piston of the preceding figures mounted on its support;
FIG. 6 is a longitudinal view in a plane intersecting both the piston and the piston support, showing the coolant supply duct; and
FIG. 7 is a longitudinal cross-section of the piston and of a portion of the piston support, highlighting the radial collectors.
DETAILED DESCRIPTION
Referring now to the above-listed drawings, numeral 1 designates as a whole a pressure die casting piston-support assembly in accordance with the invention.
The assembly comprises a support 2 having a cylindrical geometry, with a base 3 having the usual bevelled faces 4 to be engaged with tools (such as spanners or the like) for mounting the assembly onto the die casting fixture.
Extending from base 3 , support body 5 is axially hollow and has, at its front end, grooves 7 extending outwards from the centre, which will be described in detail later on. On support body 5 there are seats 9 to be engaged with piston clamping keys 10 ; in this example, seats 9 are three, spaced by 120°: their number may however be greater or smaller than three, depending on specific requirements.
At the bottom of seats 9 there is a threaded hole 11 having the same diameter as the shank of screws 12 used for securing the keys 10 .
Finally, along the piston support body 5 there are annular grooves 13 ′, 13 ″ and 13 ′″ for respective ring-type sealing gaskets (O-rings) 15 ′, 15 ″ and 15 ′″; the number of grooves and gaskets may differ from this example, but the number suggested herein ensures optimal coolant circulation in the wall.
Referring now to piston 20 , it comprises a cylindrical side wall 21 closed at the front by a head 22 , around which a sealing ring 23 is applied.
According to a preferred embodiment, sealing ring 23 has radial inner teeth 24 to be engaged into matching seats 25 obtained in the base of piston head 22 .
The outer surface of ring 23 may be smooth, like most known rings, or it may have a groove 26 which in this example has a fret design, as can be seen in the drawings, but may also have an annular or a different profile.
Radial apertures 29 in the wall 21 align with seats 9 when the piston is mounted on support 2 , thus allowing for the insertion of keys 10 : the latter lock wall 21 to support body 5 , preventing it from turning or moving axially.
Clamping the piston by means of keys is the preferred solution of the invention, because the piston is locked securely to support 2 both rotationally and translationally; however, this is not the only feasible method.
For example, a conceivable alternative may be a traditional threaded system allowing the piston to be screwed onto piston body 5 , or else a bayonet-type system, both of which are known in the art.
For cooling piston 20 , channels 30 are obtained in cylindrical wall 21 and extend parallel to one another along the wall generatrices, between an annular distribution chamber 32 encircling the front end of support body 5 and an annular collection chamber 33 .
The collection chamber is arranged at the wall base, in the space defined between two seats 13 ′, 13 ″ for respective sealing rings 15 ′, 15 ″.
The liquid collected in chamber 33 can thus flow towards a series of radial collectors 35 formed inside body 5 of support 2 .
As aforesaid, the latter is hollow axially; in particular, cavity 38 passing through it in the longitudinal direction houses a pipe 40 (sectioned in FIG. 6 ) which delivers the coolant to the end of body 5 .
From there, the coolant flow branches off into grooves 7 to reach the above-mentioned distribution chamber 32 , and then follows the path along channels 30 .
Coolant evacuation takes place along a path outside pipe 40 : the coolant flow coming from collection chamber 33 is conveyed axially by collectors 35 into the interspace surrounding pipe 40 , from where it flows on inside base 3 of support 2 to be drained out.
In this respect, it should be pointed out that the position of ring-type gaskets 15 ′, 15 ″, 15 ′″ and of respective seats 13 ′, 13 ″, 13 ′″ on support body 5 turns out to be particularly advantageous for piston cooling, in that it prevents any coolant leakage.
In fact, the coolant is fed axially to distribution chamber 32 by pipe 40 and grooves 7 ; at this stage, the presence of gasket 15 ″ adjacent to the end of support body 5 proves to be extremely important to prevent coolant dispersion.
Thanks to this seal, in fact, the liquid will flow on from grooves 7 to distribution chamber 32 and then into channels 30 , downstream of which it will enter collection chamber 33 ; in this case as well, it must be highlighted that, if gaskets 15 ′, 15 ″ were not present, the liquid would spread between the inner wall of wall 21 and body 5 instead of flowing through radial collectors 35 to be evacuated.
In other words, locating collectors 35 in the region comprised between sealing gaskets 15 ′ and 15 ″ is important for cooling the piston properly.
Moreover, it is barely worth mentioning that, although in this example the gaskets are installed into seats 13 ′, 13 ″ formed on body 5 , said seats may alternatively be obtained on the inner wall of the wall.
Finally, as a further characteristic feature of the invention, it is necessary to point out that in this example, for mechanically drilling the channels 30 into the wall (by using a cutter, a drill or the like), a tool penetrating into the wall 21 from the lower edge thereof has been advantageously used: this is a low-cost solution, since it can be implemented by using traditional machinery and tools.
Sealing elements 42 are used for closing tool entry holes 41 (visible in FIG. 4 ); these may be removable elements provided, for example, in the form of threaded plugs (of course, entry holes 41 will have to be threaded too), or permanent elements obtained by lead sealing or through deformable caps or bushes.
Removable plugs bring the advantage of allowing maintenance of channels 30 , even though the latter are generally more costly to make (in addition to tapping holes 41 ), whereas lead sealing or using non-removable, permanently deformable caps is to be preferred for small piston applications.
It can be easily understood from the above description how piston 20 can solve the technical problem addressed by the invention.
In fact, it is apparent that, since channels 30 that carry the coolant are obtained inside piston wall 21 , the thermal exchange between coolant and piston is considerably improved; as a result, more heat is removed, all other conditions being equal (coolant flow rate, temperature of the molten metal to be die cast, die casting speed, etc.).
In particular, it must be observed that in this case the coolant exchanges heat with a generally larger surface than in prior-art pistons.
In fact, in the latter the liquid only touches the inner wall of the piston wall, which wall has a shorter radius than the inner region comprised between channels 30 and the outer surface of wall 21 ; in addition, according to the present invention the liquid exchanges heat with the whole inner wall of channels 30 , the area of which, if said channels are sized appropriately and in a sufficient number, is larger than the inner surface of the piston wall.
It must also be added that the presence of channels 30 in the wall 21 , i.e. the presence of gaps in the latter's wall, reduces its heat-conductive metallic mass (of copper or the like) and hence the wall's thermal capacity (as known, thermal capacity is given by the relation Q=c×M×ΔT, where c is the specific heat of the material, M is the overall mass thereof, and ΔT is the temperature variation).
It follows that in the present invention the coolant is put into thermal exchange with a smaller metallic mass, and therefore, the flow rate being equal, it is necessary to remove less heat in order to cool down said mass.
These advantageous effects are attained without modifying the outside dimensions of piston 20 , which is thus compatible with the existing ones and can be used on die casting fixtures currently in use.
It must nevertheless be remarked that channels 30 may also be obtained through a different type of machining, e.g. by laser or electroerosion.
In such a case, tool entry holes 41 may be unnecessary, and even the shape of channels 30 may not be straight as in the example shown. For example, it may be conceivable to provide a spiral channel extending along the wall 21 .
It should also be pointed out that wall 21 , though preferably made in one piece, may however also be obtained by coupling together two pieces, i.e. an external sleeve coupled to a tubular inner part.
In such a case, channels 30 or the single spiral channel may be obtained on one of the two pieces coupled together, still obtaining a wall equivalent to that of the example described above, wherein the wall is a single piece.
In this frame, the invention also achieves further advantages related to the particular technical solutions employed.
For example, keys 10 allow piston 20 to be firmly locked onto support 2 , preventing them from turning and moving axially relative to each other, while still remaining easily accessible from the outside, in order to be removed by undoing bolts 12 , at every maintenance inspection.
Likewise, radial teeth 24 on sealing ring 23 and seats 25 on piston 20 allow the sealing ring to be locked to the piston; to this end, the ring is preferably of the open type, i.e. it has a cutout that allows it to expand elastically, so that it can be easily removed when necessary.
It is apparent that both the key-type piston clamping system and the radial-tooth-type ring locking system may be replaced with different solutions, like those used for prior-art pistons.
As far as the sealing ring is concerned, it is finally necessary to underline that the groove provided on its outer surface, which improves the lubrication of the piston to advantage of the die casting process, may be omitted without jeopardizing the other effects achieved by the invention.
These variants will still fall within the scope of the following claims. | A pressure die casting piston assembly has a pressure die casting piston. The die casting piston has a front head, a substantially cylindrical side wall extending upwardly from the front head in fixed position relative thereto. A cup-shaped chamber is defined by the front head and the side wall. The side wall is closed by the front head. The die casting piston has a coolant channel passing through the side wall to allow a coolant to pass through the side wall and within the side wall. | 1 |
BACKGROUND OF THE INVENTION
The present invention relates to a novel paving apparatus which is especially useful in paving shoulders of roadways.
Paving of hard surfaces often requires the laying of asphalt, concrete and the like on the periphery or shoulder. Such a paving process usually entails a two step method in that the shoulder is paved first and the adjacent roadway second. In the past devices such as the apparatus described in the U.S. Pat. No. 4,268,187 have been employed. Although such prior art apparatuses have satisfactorily screeded or leveled the upper surface of the paving compositions, the edge often extends over the adjacent the roadway. Thus, a lap joint is formed between the paved roadway and the paved shoulder which is not acceptable for use with large aggregate asphalt compounds. Lap joints tend to bleed to the surface causing a slippage hazard to vehicles. Also, such bleeding detracts from the appearance of the roadway. To complicate matters, the shoulders of roadways are often of varying widths. In the past, the edge of the shoulder pavement has been aligned manually or with make-shift panels on conventional pavement boxes. With the latter method any change in shoulder width required jacking of the pavement box for movement of the panel. Such methods are wasteful of labor and material.
A paving apparatus which solves the problems encountered in the prior art would be great advance in the construction industry.
SUMMARY OF THE INVENTION
In accordance with the present invention a novel and useful paving apparatus which lays paving composition on the shoulder for abutment with paving composition on the roadway proper is provided.
The apparatus of the present invention utilizes a carriage which has a lower surface being capable of rolling or skidding relative to the surface to be paved. Typically, the carriage is dragged along the surface to be paved by a vehicle carrying paving material. The carriage is generally ruggedly constructed and includes a receiver for accepting and holding paving material. The receiver may take the form of a hopper or other open funnel-like structures.
Material is placed in the receiver or hopper and is then transported to a container. An auger may be placed in the receiver to transport material therefrom to the container. A motor may be employed to motivate the auger, in this regard. Such container possesses a base portion and side wall portion to form an open chamber. The chamber has an entrance and exit, the former being in communication with the receiver.
Means is also provided for moving a portion of the side wall forming the chamber to change the volumetric capacity of the chamber and to change a dimension of the exit from the chamber. In other words, the width of the paving material exiting the chamber onto the road shoulder of the roadway possesses a predetermined width. Such means may include a partition which moves within the container and threadingly engages a threaded lead screw spanning a portion of the carriage. Again, a motor may be employed to rotate the lead screw and thus move the partition across the container forming the variable width chamber exit of the chamber. Guides may be employed to smoothly move such partition within the container. Such guides would also span the carriage, generally parallel to the lead screw heretofore described.
The apparatus of the present invention also includes means for regulating the height of paving material exiting the chamber, the width of which is fixed by the movable partition. Such means may take the form of a skimmer or screed plate which is placed immediately adjacent the exit of the container chamber. The screed plate adjusts upwardly and downwardly to regulate the thickness of the material placed atop the surface being paved.
In addition, means may also be employed to determine the surface characteristics of the paving material. A flexible plate is positioned to press downwardly on the upper surface of the paving material passing beneath the screed plate. The flexible plate possesses means for adjusting the downward pressure of the same. Both the screed plate and the flexible plate include manual adjustments which are accessible from the top of the carriage. In this regard, the carriage includes a platform permitting the operator to ride on the carriage during the paving process in order to observe the shoulder paving process and to make adjustments to the width, thickness, and quality of the upper surface of the paving material laid by the apparatus of the present invention.
It may be apparent that a novel and useful paving apparatus has been described.
It is therefore an object of the present invention to provide a movable paving apparatus which continuously easily adjusts the width of the strip of paving material being laid on the surface to permit an eventual butt joint between the shoulder area and the main roadway area of a highway.
Another object of the present invention is to provide a paving apparatus which greatly reduces labor and the waste of the material involved in paving a shoulder on a roadway to acceptable standards using prior art methods.
Another object of a present invention is capable of laying a shoulder pavement strip which precludes asphalt bleeding when combined with the pavement laid on the roadway proper.
A further object of the present invention is to provide a paving apparatus for roadway shoulders which is fully compatible with existing paving devices and equipment employed in the highway construction field.
The invention possesses other objects and advantages especially as concerns particular characteristics and features thereof which become apparent as the specification continues.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a top plan view of the paving apparatus of the present invention.
FIG. 2 is side elevation view taken along line 2--2 of FIG. 1
FIG. 3 is a sectional view taken along line 3--3 of FIG. 1.
FIG. 4 is a section view taken along line 4--4 of FIG. 1 depicting the screed plate adjustment mechanism.
FIG. 5 is a sectional view taken along line 5--5 of FIG. 1 showing the flexible plate adjustment mechanism.
For a better understanding of the invention reference is made to the following detailed description of the preferred embodiments thereof which should be referenced to the hereinabove described drawings.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Various aspects of the present invention will evolve from the following detailed description of the preferred embodiments thereof which should be referenced to the hereinabove described drawings.
The invention as a whole is shown in the drawings by reference character 10. The paving apparatus 10 includes as one of its elements a carriage 12 which is generally constructed of rigid material such as metal. Carriage 12 includes skids 14 and 16 which are bolted to side plates 18 and 20, respectively, via multiplicity of tabs 22. Wheel mechanisms 24 and 26 are also fixed to carriage 12 adjacent skid 14.
Platform 28 mounts on carriage 12 by the use of flanges 30 and 32 which are fixed to walkway 34 and to plates 18 and 20 by fastening means 36. Platform 28 slides a selected distance above the surface 38 being paved, FIG. 4. Rail 40 extends upwardly from angle member 42 to aide the operator of apparatus and to also serve as a mounting surface for controls (not shown) for motors, which will be heretofore described. It should be noted that upper portion of rail 40 is broken off in FIGS. 1 and 3.
Turning to FIGS. 2 and 3, in particular, it may be observed that apparatus 10 includes a receiver 44 having hopper 46 which accepts paving material from loading vehicle 48, (partially depicted in FIG. 3). Vehicle 48 may also serve to tow apparatus 10 via shafts 50 and pinioned to arms 54 and 56 extending from carriage 12. Apparatus moves according to directional arrows 58 and 60, FIGS. 1 and 3.
Material entering hopper 46, represented by arcuate arrows 62 of FIG. 3, passes downwardly into auger 64. Auger 64 mounts to plates 18 and 20 and rotates on bearings 66 and 68, thereat. Motor 70, which may be electric or hydraulic, is also mounted to plate 18. Controls, including wires and hoses, have been omitted for the sake of simplicity in the drawings. However, such motor controls may be positioned on rail 40 The turning action of auger 64 generally moves the paving material from hopper 46 along auger 64 away from the motor 70. The paving material 72, FIG. 3, then passes through discharge opening 74 of receiver 44 per arrows 76.
Paving material 72 flowing from opening 74 of receiver 44 passes to a container 78 having a bottom portion 80 and wall portion 82. A chamber 84 is formed by bottom portion 80 and wall portion 82 to hold paving material 72. A partition 86 of wall portion 82 is positioned opposite a portion of plate 20 also forming a part of wall 82. Means 88 is also provided for moving partition 86 which changes the volumetric capacity of chamber 84 and determines the width of exit opening 90 from chamber 84. Directional arrows 92 depict such egress of paving material 72 from chamber 84 the width of such paving material is, of course, ordained by the width of exit 90. Means 88 is shown in the preferred embodiments as including a lead screw 94 which is rotated by electric or hydraulic motor 96 as is the case with motor 70. Motor 96 is also mounted to plate 18. Bearing 98 fixed to plate 20 permits the turning of the end of lead screw 94 opposite motor 96. Partition 86 possesses a threaded block which threadingly engages lead screw 94. Bushings 102 and 104 pass along rods 106 and 108 which span and are supported by plates 18 and 20. Thus, rods 106 and 108 serve as means 110 for guiding the translational motion of partition 86 relative to lead screw 94. In essence, partition 86 may move along container 78 according to directional arrows 112.
The height of paving material 72 exiting container 78 is controlled by a skimmer or screed plate 111. Screed plate 112 is fixed to angle member 42 as depicted in FIG. 1. Screed plate 112 is split into two portions as is the case with angle member 42. Means 114 adjusts the crown on paving material 72 subsequent to leaving opening 90 of container 78. Crown adjustment means 114 includes threaded members 116 and 118 captured by threaded block 120. Threaded members 116 and 118 possess opposite pitches such that the turning of block 120 either separates or brings together threaded member 116 and 118. Threaded members 116 and 118 are mounted to the top of the split portions of angle member 42. Thus, the bottom of split screed plate 112 either forms a slight vee upwardly or downwardly.
In addition, ends of screed plate 112 are adjustable upwardly and downwardly, FIG. 4, by control wheels 122 and 124. Angle member 42 is mounted to a plate 126 which lies against side plate 18 of carriage 12. Slot 128 through side plate 18 of carriage 12 accommodates bolts and nuts 130 and 132 which hold plate 126 of angle member 42. The loosening of bolts and nuts 130 and 132 permits angle member 42 and plate 126 to slide vertically. It should be noted that bolts 130 and 132 correspond to bolts and nuts 134 and 136 with regard to slot 138 through plate 20, FIG. 2. Bolts 130 and 132, as well as bolts and nuts 134 and 136 must also be loosened before crown adjustment means 114 may be employed, heretofore described. Threaded boss 140 fixes to plate 142 atop carriage 12. Nuts 144 and 146 are held to the stem 148 of control wheel 122. Nuts 144 and 146 pinion yoke 150 into position around stem 148. Yoke 150 is connected by fastening means 152 to screed plate and angle member 42. Thus, screed plate 112 travels upwardly and downwardly when control wheel 122 is turned. As heretofore mentioned, the same mechanism applies to control wheel 124 and the portion of screed plate 112 linked thereto.
Turning to FIG. 5 it may be observed that flexible plate 154 is also employed to smooth the upper surface 156 of paving material 72. Flexible plate 154 may be a rubberized sheet, a sort of squeegee. Flexible plate 154 nests in a sheath 158 and fastens to paddle 160 by fastening means 162. Paddle 160 is itself linked to rotatable rod 164 supported across carriage 12 by bearings 166, 168 and 170. A pair of fingers 172 are fixed or otherwise connected to rod 164. Finger pair 172 is also fixed to threaded shaft 174 via rod 176, nuts 178 and 180, and is pinioned to threaded shaft 174 in conjunction with shims 182 and 184. Block 186 threadingly engages threaded shaft 174 such that block 186 and threaded shaft 174 rotate about rod 188 with the rotation of the pair of fingers 172 and the paddle 160 about rod 164. Threaded block 186 is held to angle member 42 by the use of parallel plates 190. It should be observed, that bearings 166 and 168 are connected to end plates 192 and 194, respectively. Plates 192 and 194 include slots 196 and 198, respectively. Fasteners 200 and 202 pass through plates 18 and 20 of carriage 12 as well as slots 196 and 198. Thus, the loosening of fasteners 200 and 202 permit rod 164 to be raised and lowered relative to surface 38. Of course, fasteners 200 and 202 must be loosened in conjunction with the fasteners associated with slots 128 and 138 used to adjust screed plate 112. Crank handle 204 is turned to rotate flexible plate 154 into position above surface 156 of paving material 72. Movement along directional arrow 206, FIG. 5, generally increases the pressure of flexible plate 154 on surface 156 of paving material 72.
In operation, carriage 12 is dragged or otherwise motivated along surface 38 to be paved. Paving material 72 is fed into hopper 46 from loading vehicle 48 and passed into receiver 44. Auger 64 moves the paving material 72 through exit 74 and into a chamber 84 formed in container 78. Movable partition 86 is adjusted by means 88 utilizing motor 96 to turn lead screw 94. Such adjustment would take place when the operator of apparatus 10 is in the vicinity or on top of walkway 34. Thus the edge 208 of paving material 72 passing from apparatus 10 may be very accurately adjusted by use of means 88. As heretofore described, such accurate fixation of edge 208 of paving material 78 permits butt joints between a shoulder being paved by apparatus 10 and the pavement and on the road proper. Normally, the road proper is paved after paving material 72 is laid on top of the shoulder of the roadway. The height of the paving material and exit 90 is adjusted by control wheels 122 and 124 which raise and lower screed plate 112. Likewise, the width of paving material exiting chamber 94 through opening 90 is adjusted by means 88 which positions movable partition 86 within container 78. The surface texture of paving material 72 passing from chamber 84 is smoothed by flexible plate 154. The pressure of flexible plate on the surface 156 of paving material 72 is adjusted by crank handle 204. Means 114 may also be employed to place a crown on paving material 72 by turning block 120.
While in the foregoing embodiments of the present invention have been set forth in considerable detail for the purposes of making complete disclosure of the invention, it may be apparent to those of skill in the art that numerous changes may be made in such detail without departing from the spirit and principles of the invention. | A road shoulder paving box, movable along a surface to be covered with paving material including carriage. The carriage rolls or skids along the surface to be paved and provides a receiver for accepting and holding paving material. The carriage also includes a container supported by the carriage having a chamber formed by a base and side wall portion. Such chamber includes an entrance and exit, as well as a movable partition for changing the volumetric capacity and the dimension of the chamber exit. The receiver and chamber are connected on the carriage of the paving apparatus such that paving material is transported or augered from the container to the receiver chamber. | 4 |
FIELD OF THE INVENTION
This invention relates to the manufacture of integrated circuit (IC) chips, and more particularly to a method of forming a plurality of passivated IC chips of various sizes, with guard rings and input-output (I/O) pads, from a borderless gate array wafer.
BACKGROUND OF THE INVENTION
IC chips are the heart of practically all modern electronic devices. They are typically manufactured by forming one or more arrays of unconnected gates or transistors on a silicon wafer, and then metalizing the array through masks to form interconnections between gates, and between gates and connection pads, that gives a chip its individuality and functionality.
Wafers are typically available in two types: standard-size arrays and borderless arrays. In the standard-size type, a set of individual arrays of a standard size are formed on each wafer, together with surrounding I/O pads and appropriate passivation structures for chemical isolation against environmental contaminants, as well as guard rings for electrical isolation against stray electromagnetic interference. After the interconnections have been formed, the wafer is cut between the arrays to provide individual finished chips.
In the borderless array type of wafer, a single array is formed to cover the entire surface of the wafer. Individual ICs are produced, after the formation of interconnections, by cutting through unused portions of the array. This method does not, however, lend itself to passivation.
Masks for the production of wafers and the formation of interconnections are extremely expensive, so that the manufacture of custom wafers is not economically practical for the production of chips in quantities less than hundreds of thousands. Yet there are many instances in which only a few thousand chips of any particular design are required. In order to economically produce such quantities, a wafer must be able to carry a large number of IC arrays of varying sizes for different purposes and/or different customers. This allows many different IC chips to be produced simultaneously with a single mask.
Problems arise in carrying out the latter method with either of the traditional types of wafers. In a standard-size array wafer, the array size must be large enough to accommodate the largest IC to be produced on the wafer. Consequently, substantial portions of the array are wasted for smaller ICs. Borderless arrays can be cut as desired to fit various-sized ICs on a wafer without substantial waste; however, borderless arrays, which are uniform throughout the wafer surface, do not lend themselves to passivation. Passivation structures can only be formed where the wafer substrate is accessible, i.e. where no transistor array has been formed on the wafer.
It is therefore desirable to provide a fabrication method which allows many ICs of varying sizes to be formed on a uniform generic wafer, yet allows passivation structures and guard rings to be formed around each individual IC regardless of its size or shape.
SUMMARY OF THE INVENTION
The invention overcomes the deficiencies of the prior art by forming on the surface of the wafer a borderless array composed of micro arrays or blocks about 200×200 μm in size, separated by about 10 μm wide strips in which the substrate is exposed. ICs are formed by metalizing sets of blocks which together have the requisite size and shape for the desired IC. The strips consume about 10% of the wafer surface, but the exposure of the substrate in the strips makes it possible to form passivation structures and (by forming areas of p + and/or n + diffusion in the strip) guard rings around any selected set of blocks. The 10 μm gap between blocks is not sufficient to interfere with the transmission of signals between gates in adjacent blocks.
In an additional aspect of the invention, unused blocks or portions of blocks within the layout of a particular IC may be metalized to form input/output connection pads. The versatility of the wafer can be improved by providing alternate rows or columns with various types of application-specific gate elements, such as transistors designed for use in analog or digital circuits; mixtures of transistors and resistors; or combinations of these.
In still another aspect of the invention, a variety of different layers and/or circuits can be metalized with a single mask by arranging all necessary patterns on the mask, and then covering all except the desired pattern during exposure.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a plan view of a prior art wafer;
FIG. 2 is a plan view of the inventive wafer;
FIG. 3 is an enlarged partial cross section of a wafer according to the invention;
FIG. 4 a is a plan view of one form of block;
FIG. 4 b is a plan view showing exemplary metallizations of the block of FIG. 4 a;
FIG. 5 is a plan view of another form of block;
FIG. 6 is a perspective view illustrating the use of separate masks for each layer;
FIGS. 7 a and 7 b are plan views of multi-layer masks according to the invention; and
FIG. 8 is a plan view illustrating the use of the mask of FIG. 7 a.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIG. 1 illustrates a typical conventional wafer 10 . Individual gate arrays or dies 12 surrounded by connection pads 14 are formed on the surface of wafer 10 in a row-and-column pattern. The dies 12 with their connection pads 14 are separated from one another by wide vertical and horizontal scribe lines 16 v and 16 h . The marks 18 allow precise registration of the metalizing masks with the dies 12 during the subsequent metalizing operation in the manufacture of ICs. p + and n + diffusions for guard rings are formed in the scribe lines 16 v and 16 h around the dies 12 concurrently with the gate arrays 12 , and metallic passivation structures are formed along the peripheries of the dies 12 concurrently with the formation of the metallic connection pads 14 . Following metalization, the wafer 10 is cut along the scribe lines 16 v , 16 h to produce individual IC chips.
In a typical wafer such as that depicted in FIG. 1, the dies 12 may be, for example, about 2 mm by 3 mm in size. In general, the granularity of this type of wafer is in the millimeter range.
FIG. 2 shows a wafer 20 according to the invention. The dies on the wafer 20 are formed as small blocks 22 without connection pads (i.e. blocks in which the transistors or gates occupy essentially the entire width and height of the block), and are about 200×200 μm in size. The blocks 22 are separated by scribe lines 26 v and 26 h about 10 μm wide, in which the wafer substrate is exposed for the formation of guard ring diffusions 36 , 38 , 40 (FIG. 3) and alignment marks 34 . The granularity of the inventive wafer 20 can thus be in the 100-200 μm range. Any desired number of blocks can be combined together during metalization, in sets such as 23 and 25 , as described below to form IC chips of any desired size. This makes it possible to fabricate a variety of chips of different sizes on a single wafer.
FIG. 3 illustrates the ability of the inventive structure to provide guard rings and passivation structures around any desired set of the blocks 22 . In FIG. 3, 30 denotes the p− substrate of the wafer 20 . 22 a , 22 b and 22 c are blocks of transistors. Block 22 a is a circuitry block which, together with other adjacent blocks, forms part of an integrated circuit. Block 22 b is a block used to support an input/output connection pad 32 , and block 22 c is an unused block. The wafer 20 may eventually be cut through the block 22 c , or on the scribe line 26 . Alignment marks 34 for that purpose are made on the substrate 30 .
Each of the scribe lines 26 contains guard ring connections 36 , 38 . The connections 36 are preferably p+ diffusions in the p− substrate 30 , while the connection 38 is a p− diffusion in an n+ diffusion 40 in the p− substrate 30 . The diffusions 36 , 38 are connected to guard ring areas 42 , 44 , respectively, on the perimeter of the outermost circuitry block 22 a by metalization layers 46 , 48 separated by an insulation layer 50 .
A selected transistor 52 of the circuitry of block 22 a may be connected to the input/output pad 32 by a metalization 54 deposited over an insulation layer 56 . The transistors in block 22 b are unconnected and inactive. A metalization like 54 may also be used to interconnect transistors on adjacent blocks to form a multi-block circuit.
A passivation structure 58 connected to the substrate 20 can be formed during metalization around the periphery of the set of blocks 22 which, after cutting of the wafer, will constitute the finished IC chips.
The block approach of this invention lends itself well to the manufacture of various chip configurations. For example, the blocks 22 may, for example, contain rows or columns of alternating fixed-length strips of n− transistors and p− transistors 59 for digital use (FIG. 4 a ). The transistors 57 , 59 can be interconnected with each other and with input-output pads 61 by metalization interconnections 63 (FIG. 4 b ). Alternatively, the blocks 22 may contain analog cells or strips 65 that have special function transistors 67 at each end (FIG. 5 ), resistive or other components 69 , or mixtures of these.
In view of the high cost of metalization masks, it is highly desirable in chip manufacture to reduce their number. Typically, a separate mask 60 a , 60 b , 60 c (FIG. 6) is provided for each metalization layer to form successive layer patterns A 1 , A 2 and A 3 . In accordance with the invention, a single mask can frequently be shared by several layers in which patterns are repetitive. This can be done by placing all of the patterns A 1 , A 2 and A 3 (or, for example A 1 through A 3 and B 1 through B 6 for a multi-project wafer) onto a single mask 62 a or 62 b (FIGS. 7 a and 7 b ), appropriately aligning the mask for each layer, and then blocking off all but the desired pattern with an opaque cover 64 (FIG. 8) so that only the desired pattern is exposed. The exposure in this approach must, of course, be carefully controlled.
It will be seen that the present invention provides a versatile, cost-saving and area-efficient method of fabricating different kinds and sizes of IC chips on a single borderless gate-array wafer with improved passivation while providing guard rings and alignment marks on the wafer substrate, that are effectively usable for all shapes and sizes of ICs. It should be understood that the method described herein and shown in the drawings represents only a presently preferred embodiment of the invention. Various modifications and additions may be made to that embodiment without departing from the scope and spirit of the invention. | Effective passivation structures and guard rings can be formed in borderless gate arrays by forming the gates in an array of discrete blocks separated by thin scribe lines in which the substrate is not covered by gates. Diffusions for guard rings can be formed in the substrate for guard ring purposes, and passivation structures can be sealingly attached to the substrate. Various circuit metalizations such as discrete layers or different circuits can be produced with a single mask by covering all but a selected portion of the mask during exposure. | 7 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims priority to U.S. Provisional Patent Application No. 60/809,950, filed May 31, 2006 and entitled “DISPLAY STAND AND METHOD”.
FIELD OF THE INVENTION
[0002] The invention relates to the field of display stands for consumer products, and particularly to a display stand comprising at least one video device.
BACKGROUND
[0003] Traditionally, retail stores employ display stands to exhibit goods, so that a customer can view and purchase certain products. The presentation of the goods can have an impact on the sales volume. For example, display stands which are positioned at the ends of grocery store product aisles, or which are placed in the vicinity of check-out lanes, are more visible to a consumer and thus produce a higher sales volume. Display stands which show colorful or attractive packagings, or which have a variety of related goods, can also pique the consumers' interest and generate a higher sales volume for the displayed goods. Thus, it has long been an axiom of the retail industry that creating visibility for product, followed by creating interest for the product, is the key to successful sales.
[0004] Retailers may also place posters or other print advertising, or even video monitors, in the store window to create interest in certain products. Such window displays entice customers to enter the store, where the retailer then relies on traditional display means to induce them to purchase certain goods.
[0005] Recently, retailers are offering in-store attractions to entice customers to enter the establishment. For example, stores or restaurants can employ live performers, contain play areas for children, provide video games or arcades, or offer other amusements. Customers are drawn into the store by these amusements, and are then induced to purchase certain products. Retailers may also offer services related to the goods which are sold; for example, a pet store may offer dog grooming services. Customers will be attracted to the pet store for the grooming service, and will likely also purchase pet-related goods while in the store. However, as with the window displays discussed above, the retailer relies on traditional display means to induce customers to purchase goods once they have entered the store.
[0006] In an effort to increase the visibility of products, some retailers employ display stands with large “frontage” areas for displaying goods. Such stands are typically dimensioned to be long and shallow, so that the consumer can view most or all of the goods on a given shelf. However, the size and shape of such stands can make them difficult to use in terms of in-store placement, or in terms of efficiently replacing goods which may have been sold out.
[0007] What is needed, therefore, is a display stand which simultaneously creates visibility for a product and creates interest for the consumer in the product. Desirably, the display stand will have dimensions allow for efficient in-store placement and replacement of sold-out goods, and will induce consumers to purchase a higher volume of displayed products that traditional stands.
SUMMARY
[0008] This invention provides a display stand comprising at least one video device, which is dimensioned to hold at least one container of product, such that the product is viewable by a consumer.
[0009] The invention further provides a method of marketing products, comprising providing a display stand of the invention and stocking the display stand with a plurality of related products, and exhibiting video content on the video device. The exhibited video content is also related to the products, and is designed to visually and aurally attract consumers to the display stand and generate interest in purchasing the displayed products.
BRIEF DESCRIPTION OF THE DRAWING
[0010] For the purpose of illustration, there are shown in the drawings forms which are exemplary; it being understood, that this invention is not limited to the precise arrangements and instrumentalities shown.
[0011] FIG. 1 is a perspective view of an exemplary display stand.
DETAILED DESCRIPTION
[0012] The display stand comprises at least one video device which is positioned on the stand so that it can be viewed by a consumer in proximity of the stand. The stand further comprises a frame comprising at least one support unit, such as shelving or brackets, for holding at least one container of product to be displayed. The at least one support unit is attached to portions of the display stand as is known in the art. For example, shelving or brackets can be attached to posts or panels which form the back of the display stand, and extend towards the front of the stand. In one aspect, the support units are positioned in the display stand at a slight downward angle from the back to the front of the stand, so that a product container placed on the support can be more readily viewed by a consumer.
[0013] An exemplary display stand 100 is shown in FIG. 1 . The stand comprises a rectangular bottom portion 110 constructed from front and back substantially parallel elongated beams 110 ′ connected by right and left side elongated beams 110 ″. Beams 110 ″ are substantially parallel to each other but substantially perpendicular to front and back beams 110 ′, and are shorter than beams 110 ′. Beams 110 ′ and 110 ″ can be tubular, rectangular, square, L-shaped, or any suitable shape which conveys sufficient structural strength to the display stand. Bottom portion 110 may be of unitary construction, or can comprise multiple pieces. If bottom portion 110 comprises multiple pieces, then the pieces can be fastened together by any suitable means, for example by screws, bolts, rivets, clamps, friction fits, welds and the like.
[0014] Bottom portion 110 may optionally have a caster 115 fastened (either permanently or removably) to each corner or other devices by which the display stand can be readily moved. The casters or other device are positioned such that they contact the floor and support the display stand.
[0015] Right and left back posts 125 are connected to bottom portion 110 and extend upwardly and substantially perpendicular to the bottom portion. The top of back posts 125 are connected to a top portion 130 , which comprises right and left side beams 135 and back beam 140 . Beams 135 and 140 can be tubular, rectangular, square, L-shaped, or any suitable shape which conveys sufficient structural strength to the display stand. As with the bottom portion, top portion 130 may be of unitary construction, or can comprise multiple pieces fastened together as discussed above.
[0016] A plurality of support units 145 are attached to back posts 125 . For example, the display stand can contain one, two, three, four, five, eight, ten, twenty, twenty-five or more support units. The support units comprise right portion 150 ′ and left side portion 150 ″, which are attached by their back ends to the back posts and extend outward towards the front of the stand at a slight downward angle A. The right and left side portions 150 ′ and 150 ″ are flat and elongated, and have a slight upwardly extending flange 155 on the front end. Thin, elongated beams 160 extend between right portion 150 ′ and left side portion 150 ″ and form a bottom frame for each support unit 145 . A product container (not shown) can be set onto and held by this bottom frame and side portions 150 ′ and 150 ″. Another thin, elongated beam 165 extends between right portion 150 ′ and left side portion 150 ″ at the level of flange 155 , and acts as a stop to keep product containers from sliding forward out of the stand. The thin, elongated beams 160 and 165 can be tubular, flat, rectangular, L-shaped, or any other suitable shape. The support units 145 can extend to the front edge of the stand (defined in FIG. 1 by front beam 110 ′), can extend past the front edge of the stand, or (as illustrated in FIG. 1 ), can extend only part of the way to the front edge of the stand.
[0017] Top portion 130 supports casing 170 , which houses at least one video device 175 comprising screen 180 . The casing 170 also houses any electronics necessary for the operation of video device 175 , as described in more detail below. It is understood that the display stand can comprise a video device supported by the top portion without a casing. In the aspect illustrated by FIG. 1 , the video device 175 is positioned above the plurality of support units 145 , and is facing forward so that a consumer can view both the video device and the containers of displayed product simultaneously. One or more access ports (not shown) may also be present in casing 170 so that the video device 175 can be reached, for example to repair the device or change the video content.
[0018] It is understood that the one or more video devices comprising the display stand can be positioned anywhere on the stand; for example above, below or in between the support units, or any combination thereof. Multiple video devices can be positioned to be viewed from virtually any angle (e.g., front, back, side or sides) as is convenient. The video device(s) can also be positionable, so that they can be moved to a suitable position and angle depending on the configuration of the display stand and the environment surrounding the stand in a given retail establishment.
[0019] The one or more video devices comprising the display stand can be any suitable video display and playback unit (including speakers or other device for producing sound) which is commercially available, such as a video monitor operably connected to a video tape machine (e.g., a video cassette recorder or video cassette player which can record and/or play video tapes such as VHS or Beta tapes), digital video disc (DVD) player/recorder, laser disc player/recorder and the like. The video device can also comprise a broadcast, cable or satellite television signal receiver, which can receive and play suitable video signals. The video device can also comprise a computer with a central processing unit and in input/output device, which can comprise a disk drive, magnetic tape reader, or the like which can store and provide video content for viewing. For example, the input/output device can accept and read a compact flash memory card or other storage device such as a memory chip or stick (e.g., a memory stick which can be inserted into a USB port) which can store and transfer video content. It is understood that the video device can comprise one, some or all of the formats discussed above (e.g., a combination video tape and DVD machine). It is also understood that the video content exhibited by the video device can also comprise an audio component.
[0020] The video display can be any suitable size which allows for viewing of the video content, and can be, for example, about 150 mm in length and about 150 mm in width. Other sizes for the video display are contemplated.
[0021] The display stand can comprise one or more motion sensors, heat sensors, sound sensors or the like which sense the presence of a consumer in the area surrounding the display stand. For example, the video device can be triggered to play video content if a consumer walks near the display stand.
[0022] Video content which can be stored and/or broadcast by the video device include broadcast, cable or satellite TV signals, magnetic tape (e.g., video tape), digital video disks, laser disks, and computer-readable codes such as MPEG or “.wav” files, and the like, or any combination thereof. Video content can be provided to the video device by any suitable means; for example, by placing a suitable recorded or recordable medium into the device (e.g., loading a video tape or DVD), or by radio-frequency or other suitable wired or wireless transmission.
[0023] The display stand can also comprise a power supply, which can be internal (for example, a battery or battery pack), external (a plug or other power-transferring lead), or both. Internal power supplies are preferably re-chargeable. External power supplies can comprise any of a plurality of plug- or lead-types designed to mate with power supply outlets in any country. The power supply is operably connected to the video device.
[0024] Reference to “fastened,” “attached” or the like with respect to components of the display stand means that the components are joined together by any suitable means within the skill in the art; for example by screws, bolts, rivets, clamps, welds, friction fits and the like. In one aspect, the display stand is provided in pre-fabricated components which can be readily assembled at the point of use with minimal tools.
[0025] The components of the display stand can be fabricated from any suitable rigid material, such as metal, plastic, wood, cardboard, plasterboard, resin, or combinations thereof, such as are known in the art.
[0026] The display stand can be any convenient dimensions, and in one aspect is generally rectangular in shape, with the longer side comprising the front and back portions of the stand. Such dimensioning allows for greater viewing and access of the displayed product by a consumer. The display stand is also, for example, of sufficient height to display a suitable number of different products (or a suitable amount of a single product). Suitable dimensions for the display stand include: a height (i.e., bottom to top and not necessarily including casters, if any) of about 1500 mm, for example 1450 mm a width of about 600 mm, for example about 580 mm; and a depth (i.e., front to back) of about 400 mm, for example about 380 mm. The height of the casing and/or video device can be, for example, about 200 mm or about 150 mm. The distance between the bottom of one support unit and the top of the one below can be any suitable distance which allows a consumer or retailer ready access to the product in the product container; for example, this distance can be about 200 mm, for example about 150 mm. Greater or lesser dimensions for all parts of the display stand are contemplated.
[0027] The display stand is used to display one or more products which are, for example, contained in a carton or other container. The support units of the display stand is preferably dimensioned to accept at least one product container, and can optionally accept multiple (e.g., two, three, four, five, six or more) containers side-by-side. The support units are also preferably dimensioned within the display stand so that displayed products can be readily reached by consumers, and the optional slight downward angle of the support units can cause the products remaining in a container to slide forward and maintain “frontage” for the product.
[0028] The display stand can comprise other electronics separate from the video device, for example, which produce sound, light or combinations of both. These additional electronics can operate independently from the video device, or can be triggered and controlled by signals from the video device. The additional electronics can be powered by the same power supply which is operably connected to the video device, or can run from one or more additional power supplies which are not necessarily connected to the video device.
[0029] In one aspect, a display stand is provided, and placed within an establishment to induce customer to purchase goods by displaying one or more related products while exhibiting video content that is also related to the product. The establishment can by any retail store, wholesale outlent, restaurant, service provider and the like. The display stand can be placed anywhere in the establishment that is convenient and where it can be viewed by consumers entering the establishment. Display of related products on the display stand, and exhibition of the video content which is related to the products, is designed to elicit interest in the products by providing visual and aural stimulation to consumers.
[0030] The one or more video devices on the display stand can be positioned such that a consumer in proximity of the display stand can readily view the video content being exhibited. The products being displayed are also readily viewed and reached by a consumer in proximity of the display stand.
[0031] Products which are “related” or which “relate” to one another are those which have a common characteristic, are contained in packaging with a common theme, or are otherwise are associated or associable in the perception of a consumer.
[0032] For example, products which have a common characteristic can comprise, for example, toys, clothing, footwear, headgear, sporting goods, household goods, kitchenware (including flatware and other eating or serving utensils, and plates, bowls or other crockery), “do-it-yourself” or “DIY” materials (e.g., any materials for home improvement, such as tools and other hardware, lumber, paint and paint accessories, flooring, paneling, sheetrock, ceramic tile, and the like) or food such as meats, produce (e.g., fruits and vegetables or combinations thereof) and confections (including candy, cakes, cookies, gum and the like, or combinations thereof), or combinations thereof. Products with a common characteristic can also comprise, for example, products with similar pricing, or which have increasingly greater or lesser pricing within a certain price range. Products which are contained in packaging with a common theme comprise, for example, products which are packaged under a certain brand, trademark or trade dress. It is understood that a “brand,” “trademark” or “trade dress” can comprise a given color scheme, wording, symbols, pictures, recognizable set of characters or settings, or combinations thereof. Products can be otherwise associated or associable in the mid of a consumer if they are recognized by a consumer (or class of consumers) as being similar in size, shape or value.
[0033] Video content which is “related” or which “relate” to products in the display stand includes any content which the consumer recognizes as being associated with the products. For example, the video content can discuss the product features or characteristics, show consumers using the products or discussing the products, or compare the products to other competing products. The video content can also comprise characters or settings which also appear on the product packaging. For example, animated or live-action features (i.e., full-, medium- or short-length features) which include the relevant characters or settings can be played at various times, in order to induce consumers to come into proximity of the display stand and become interested in the displayed products. The animated or live-action features can also comprise the relevant characters discussing and/or using the displayed products. In one aspect, the video content can be changed or renewed by the retailer and/or the manufacturer of the display stand.
[0034] The video content can be exhibited in continuous loop, at set time intervals, at random time intervals, and/or when consumers come into proximity (such as walk by) the display stand. The video content can also be exhibited by action of the consumer, for example by pressing a button or speaking a command word (such as “play”). The video content is preferably designed to catch the attention of consumers and interest them in the products being displayed.
[0035] It is understood that the video content can comprise audio content. Thus, the video content can entice consumers into proximity of the display stand with both visual and aural stimuli. The video content can also hold consumers in the proximity of the stand once they have been initially attracted with both visual and aural stimuli.
[0036] The displayed products are placed on the support units of the stand, such that the products can be readily viewed by consumers in proximity of the stand. For example, the products are provided in containers, such as cartons or boxes, which can be readily opened and placed on the support units. In one aspect, the containers are not shrink-wrapped or the like, but the products inside are individually packaged. Such containers are known in the art, and can comprise cardboard cartons with perforated portions on their top surface. The perforated portions can be “punched-out” and lifted or moved away to reveal individual product packages contained inside. Both the container and the individual product packages can be marked with the same or similar brand, trademark or trade dress to indicate that the products are related. In one aspect, the product containers provided are dimensioned to fit substantially within the dimensions of a support unit, so that the containers can be readily placed into and removed from the stand.
[0037] One or more product containers can be placed on a given support unit. For example, two, three, four, five, six or more containers can be placed side-by-side on the support units so that the products can be readily viewed by consumers in proximity of the display stand. The products can be arranged on the various support units of the display stand in any suitable order or pattern. For example, products can be arranged on the stand in descending order of prices; for example, from products costing fractions of a dollar or euro on the top support units, products costing one to two dollars or euros on the middle support units, and products costing two or more dollars or euros on the bottom shelves. Products can also be arranged in ascending order of price. Preferably, products having the same or similar price are displayed on the same support unit. Other product characteristics can be used to arrange products in the display stand, such as size, color, complexity, popularity among the consuming public, and the like.
[0038] In one aspect, a display stand can have eight support units, with products arranged by price on each support unit as in Table 1 (with support unit “one” being the one closest to the floor, and “eight” being the one closest to the top of the display stand).
TABLE 1 Exemplary arrangement of products by price Support Unit Price (in US dollars) One 2.00 Two 1.50 Three 1.00 Four 0.75 Five 0.50 Six 0.25 Seven 0.10 Eight 0.05
[0039] In one aspect, the display stand is provided with, or manufactured for, a given set of products and/or product containers. These products or containers can then be readily placed onto the display stand support units by the retailer in order to initially set up the display stand. Product containers can also be readily replaced once the product in a given container is sold out. As described above, the optional downward angle of the support units will cause the product to slip downward as individual packages are removed by consumers, thus continually displaying the product for viewing by the consuming public and producing the perception that the container is full until the product is sold out. In one aspect, the display stand and product containers are dimensioned so that no other product containers fit readily with the display stand. This aspect can be used, for example, to prevent products which are not related to each other or to the video content from being displayed on the stand. In another aspect, display stands can be provided in a given or standard size, so that the retailer can readily replace a stand which occupies a given area with another stand. For example, a display stand from which all the goods have been sold can be replaced with a new stand which contains a full complement of goods. In this latter example, the display stands can be made from easily replaceable or disposable materials such as paper, cardboard or plastic, so that a “used” stand can be readily replaced with another, and the “used” stand can be discarded or recycled.
[0040] The display stand can also be provided with video content related to the products. In one aspect, the video device can only receive and play video content provided by the manufacturer of the stand. This aspect can be used, for example, to prevent the exhibition of video content which is not related to the products being displayed on the stand.
[0041] The display stand can also be decorated with signage or other indicia related to the displayed products and the video content. “Related” or “relates” with respect to signage or other indicia and displayed products or video content has the same meaning as discussed above. In one aspect, the display stand is provided with signage or other indicia related to the products to be displayed and the video content to be exhibited.
[0042] Other features can be included on the display stand or product containers to facilitate the display of the maximum number of products. For example, product ingredients or warnings related thereto can be printed or displayed directly on some portion of the display stand, so that it need not be printed on the product containers. Pricing of products can also be displayed directly on the stand, so that consumers can readily tell the price of a given product on a support unit. In one aspect, the prices of product in various currencies can be listed on different stickers or signs that are provided with the display stand or product containers, so the retailer can readily choose and display the appropriate price in the appropriate currency on the stand.
[0043] While the present invention has been described in connection with the aspects discussed above and the FIGURE, it is to be understood that other similar aspects may be used, or modifications or additions may be made to the described aspects for performing the same function of the present invention without deviating therefrom. Therefore, the present invention should not be limited to any single aspect, but rather should be construed in breadth and scope in accordance with the recitation of the appended claims. | A display stand is provided that comprises at least one video device, and which is dimensioned to hold at least one container of product such that the product is viewable by a consumer. The video device is designed to visually and aurally attract consumers to the display stand and generate interest in purchasing the displayed products. | 6 |
BACKGROUND OF THE INVENTION
The invention relates to a Resource Manager, and more particularly, to a technique for scheduling multiple disk requests with guaranteed completion times and writing data buffers to disk to free memory.
As electronic imaging machines become more complex and versatile in operation, there is a greater demand for higher performance and expectations from limited resources. A suitable control must be able to not only coordinate the operation of the various components of the machine such as the scanner and the printer but must also be able to schedule and allocate key control elements such as random access memory and disk or mass memory to provide the most efficient and productive operation of these components.
In the prior art, U.S. Pat. No. 4,589,093 discloses a Timer Manager for suspending tasks waiting for switch or sensor input, or waiting for a real time or machine clock delay. U.S. Pat. No. 4,338,023 teaches a technique of job recovery employing the efficient use of machine resources depending upon the type of recovery required and the particular use of the resources. U.S. Pat. No. 4,800,521 discloses a task control manager for executing a plurality of tasks concurrently.
A difficulty with the prior art machine systems is the need for sufficient memory to handle high speed resources concurrently such as scanning and printing or alternatively the need for an adequate resource manager to handle such operations. Often, the insufficiency of memory space results in error messages or re-requests to the control for memory allocation resulting in delay and prolonging of the reproduction or printing cycle. It would also be desirable to be able to provide a scheme to resolve multiple requests for memory and be able to guarantee memory availability at a predetermined time.
It is an object, therefore, of the present invention to guarantee the time when memory or a mass memory access can be completed. Another object of the present invention to predict when memory will become available and to provide requesters of memory space guaranteed time of memory availability in order that the requesters can determine a further course of action. Other advantages of the present invention will become apparent as the following description proceeds, and the features characterizing the invention will be pointed out with particularity in the claims annexed to and forming a part of this specification.
SUMMARY OF THE INVENTION
Briefly, the present invention is an electronic image processing apparatus comprising an electronic scanner and an electronic printer for forming an image, a controller for directing the operation of the image processing means, the controller including a mass memory device for storing data to be printed, random access memory, a printer and a resource manager for ensuring access to the random access memory for conveying data from the mass memory device to the printer, the resource manager including a mass memory device scheduler to provide printer access to the random access memory, the mass memory device scheduler having a reservation queue to reserve mass memory device access at predetermined times, delay means to determine that access to the mass memory device is invalid within a given time, and means to raise the priority of requests in order to provide guaranteed random access memory at predetermined times.
For a better understanding of the present invention, reference may be had to the accompanying drawings wherein the same reference numerals have been applied to like parts and wherein:
DETAILED DESCRIPTION OF THE DRAWINGS
FIG. 1 is a view depicting an electronic printing system with the job supplement of the present invention allowing building of print jobs from diverse inputs or in response to special programming instructions;
FIG. 2 is a block diagram depicting the major elements of the printing system shown in FIG. 1;
FIG. 3 is a plan view illustrating the principal mechanical components of the printing system shown in FIG. 1;
FIG. 4 is a schematic view showing certain construction details of the document scanner;
FIGS. 5A, 5B, and 5C comprise a schematic block diagram showing the major parts of the system control section;
FIG. 6 is a block diagram depicting the Operating System, with Printed Wiring Boards and shared line connections;
FIG. 7 is a flow chart illustrating disk allocation in accordance with the present invention;
FIG. 8 is a schematic of the disk access queue in accordance with the present invention; and
FIG. 9 is a flow chart illustrating the disk access queue of FIG. 8.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring to FIGS. 1 and 2, there is shown an exemplary laser based printing system 2 for processing print jobs in accordance with the teachings of the present invention. Printing system 2 for purposes of explanation is divided into a scanner section 6, controller section 7, and printer section 8. While a specific printing system is shown and described, the present invention may be used with other types of printing systems such as ink jet, ionographic, etc.
Referring particularly to FIGS. 2-4, scanner section 6 incorporates a transparent platen 20 on which the document 22 to be scanned is located. One or more linear arrays 24 are supported for reciprocating scanning movement below platen 20. Lens 26 and mirrors 28, 29, 30 cooperate to focus array 24 on a line like segment of platen 20 and the document being scanned thereon. Array 24 provides image signals or pixels representative of the image scanned which after suitable processing by processor 25, are output to controller section 7.
Processor 25 converts the analog image signals output by array 24 to digital and processes the image signals as required to enable system 2 to store and handle the image data in the form required to carry out the job programmed. Processor 25, for example, may provide enhancements and changes to the image signals such as filtering, thresholding, screening, cropping, etc.
Documents 22 to be scanned may be located on platen 20 for scanning by automatic document handler (ADF) 35 operable in either a Recirculating Document Handling (RDH) mode or a Semi-Automatic Document Handling (SADH) mode. A manual mode including a Book mode and a Computer Forms Feeder (CFF) mode are also provided, the latter to accommodate documents in the form of computer fanfold. For RDH mode operation, document handler 35 has a document tray 37 in which documents 22 are arranged in stacks or batches. The documents 22 in tray 37 are advanced by vacuum feed belt 40 and document feed rolls 41 and document feed belt 42 onto platen 20 where the document is scanned by array 24. Following scanning, the document is removed from platen 20 by belt 42 and returned to tray 37 by document feed rolls 44.
For operation in the SADH mode, a document entry slot 46 provides access to the document feed belt 42 between tray 37 and platen 20 through which individual documents may be inserted manually for transport to platen 20. Feed rolls 49 behind slot 46 form a nip for engaging and feeding the document to feed belt 42 and onto platen 20. Following scanning, the document is removed from platen 20 and discharged into catch tray 48.
For operation in the manual mode, document handler 35 is pivoted upwardly to expose platen 20. This permits the document 22 to be manually placed on platen 20 following which array 24 is operated to scan the document. When scanning is completed, the document is removed to clear platen 20 for the next document. For Book mode, the book is manually positioned face down on platen 20 with the center line of the book aligned with positioning indicia (not shown) located along the border of platen 20. By programming tile system, either one or both of the pages of the book open on the platen are scanned. The process is repeated for different pages of the book until all of the pages desired have been scanned following which the book is removed to clear platen 20.
For operation in the CFF mode, computer forms material is fed through slot 46 and advanced by feed rolls 49 to document feed belt 42 which in turn advances a page of the fanfold material into position on platen 20.
Referring to FIGS. 2 and 3, printer section 8 comprises a laser type printer and for purposes of explanation is separated into a Raster Output Scanner (ROS) section 87, Print Module Section 95, Paper Supply section 107, and Finisher 120. ROS 95 has a laser 91, the beam of which is split into two imaging beams 94. Each beam 94 is modulated in accordance with the content of an image signal input by acousto-optic modulator 92 to provide dual imaging beams 94. Beams 94 are scanned across a moving photoreceptor 98 of Print Module 95 by the mirrored facets of a rotating polygon 100 to expose two image lines on photoreceptor 98 with each scan and create the latent electrostatic images represented by the image signal input to modulator 92. Photoreceptor 98 is uniformly charged by corotrons 102 at a charging station preparatory to exposure by imaging beams 94. The latent electrostatic images are developed by developer 104 and transferred at transfer station 106 to a print media 108 delivered by Paper Supply section 107. Media 108, as will appear, may comprise any of a variety of sheet sizes, types, and colors. For transfer, the print media is brought forward in timed registration with the developed image on photoreceptor 98 from either a main paper tray 110 or from auxiliary paper trays 112 or 114. The developed image transferred to the print media 108 is permanently fixed or fused by fuser 116 and the resulting prints discharged to either output tray 118, or to finisher 120. Finisher 120 includes a stitcher 122 for stitching or stapling the prints together to form books and a thermal binder 124 for adhesively binding the prints into books.
Referring to FIGS. 1, 2 and 5, controller section 7 is, for explanation purposes, divided into an image input controller 50, User Interface (Ul) 52, system controller 54, main memory 56, image manipulation section 58 and image output controller 60.
The scanned image data input from processor 25 of scanner section 6 to controller section 7 is compressed by image compressor/processor 51 of image input controller 50 on PWB 70-3. As the image data passes through compressor/processor 51, it is segmented into slices N scanlines wide, each slice having a slice pointer. The compressed image data together with slice pointers and any related image descriptors providing image specific information (such as height and width of the document in pixels, the compression method used, pointers to the compressed image data, and pointers to the image slice pointers) are placed in an image file. The image files, which represent different print jobs, are temporarily stored in system memory 61 which comprises a Random Access Memory or RAM pending transfer to main memory 56 where the data is held pending use.
As best seen in FIG. 1, Ul 52 includes a combined operator controller/CRT display consisting of an interactive touchscreen 62, keyboard 64, and mouse 66. Ul 52 interfaces the operator with printing system 2, enabling the operator to program print jobs and other instructions, to obtain system operating information, instructions, programming information, diagnostic information, etc. Items displayed on touchscreen 62 such as files and icons are actuated by either touching the displayed item on screen 62 with a finger or by using mouse 66 to point cursor 67 to the item selected and keying the mouse.
Main memory 56 has plural hard disks 90-1, 90-2, 90-3 for storing machine Operating System software, machine operating data, and the scanned image data currently being processed.
When the compressed image data in main memory 56 requires further processing, or is required for display on touchscreen 62 of Ul 52, or is required by printer section 8, the data is accessed in main memory 56. Where further processing other than that provided by processor 25 is required, the data is transferred to image manipulation section 58 on PWB 70-6 where the additional processing steps such as collation, make ready, decomposition, etc. are carried out. Following processing, the data may be returned to main memory 56, sent to Ul 52 for display on touchscreen 62, or sent to image output controller 60.
Image data output to image output controller 60 is decompressed and readied for printing by image generating processors 86 of PWBs 70-7, 70-8 (seen in FIG. 5A). Following this, the data is output by dispatch processors 88, 89 on PWB 70-9 to printer section 8. Image data sent to printer section 8 for printing is normally purged from memory 56 to make room for new image data.
Referring particularly to FIGS. 5A-5C, control section 7 includes a plurality of Printed Wiring Boards (PWBs) 70, PWBs 70 being coupled with one another and with System Memory 61 by a pair of memory buses 72, 74. Memory controller 76 couples System Memory 61 with buses 72, 74. PWBs 70 include system processor PWB 70-1 having system processors 78; low speed I/O processor PWB 70-2 having Ul communication controller 80 for transmitting data to and from Ul 52; PWBs 70-3, 70-4, 70-5 having disk drive controller/processors 82 for transmitting data to and from disks 90-1, 90-2, 90-3 respectively of main memory 56 (image compressor/processor 51 for compressing the image data is on PWB 70-3); image manipulation PWB 70-6 with image manipulation processors of image manipulation section 58; image generation processor PWBs 70-7, 70-8 with image generation processors 86 for processing the image data for printing by printer section 8; dispatch processor PWB 70-9 having dispatch processors 88, 89 for controlling transmission of data to and from printer section 8; and boot control-arbitration-scheduler PWB 70-10.
Referring particularly to FIG. 6, system control signals are distributed via a plurality of printed wiring boards (PWBs). These include EDN core PWB 130, Marking Imaging core PWB 132, Paper Handling core PWB 134, and Finisher Binder core PWB 136 together with various Input/Output (I/O) PWBs 138. A system bus 140 couples the core PWBs 130, 132, 134, 136 with each other and with controller section 7 while local buses 142 serve to couple the I/O PWBs 138 with each other and with their associated core PWB.
On machine power up, the Operating System software is loaded from memory 56 to EDN core PWB 130 and from there to the remaining core PWBs 132, 134, 136 via bus 140, each core PWB 130, 132, 134, 136 having a boot ROM 147 for controlling downloading of Operating System software to the PWB, fault detection, etc. Boot ROMs 147 also enable transmission of Operating System software and control data to and from PWBs 130, 132, 134, 136 via bus 140 and control data to and from I/O PWBs 138 via local buses 142. Additional ROM, RAM, and NVM memory types are resident at various locations within system 2.
Efficient resource management, in particular scanner section 6, controller section 7, and printer section 8, sufficient electronic sub-system (ESS) memory and sufficient disk bandwidth are key to optimizing the performance of printing system 2. System performance is improved by minimizing the average turn-around time per job thus increasing job throughput and by minimizing the average percentage of print pitch skips per job thereby efficiently using the consumables of the machine. The basic ESS architecture consists of a limited pool of memory, system memory 61 coupled to scanner section 6 printer section 8, and a rigid spool disk 56.
All four components in accordance with the present invention are managed by a resource manager even though the input and output devices and the disk drive have their own controllers to carry out their specific functions. For example, although the resource manager does not control the scanner section 6, in terms of mechanically scanning a document it does restrict when the scanner can begin scanning by not providing enough memory to begin operating. The main function of the ESS is to allow the system to accept and execute scan/print jobs. The three basic steps of the scan/print function are 1) scan the set of originals into memory, 2) store each original as a compressed bitmap onto the spool disk 56, and 3) print the desired number of copies of the set of originals. The resource, manager executes each of the three steps concurrently.
Because of the limited amount of memory 61 in the system, there comes a point in time when the system requires an image, not currently residing in memory but stored on the spool disk 56, to be in memory, and there is not enough available memory to hold the compressed bit map form of the image. The resource manager must then decide which of the pages currently in memory would be best to remove from memory to make room for the incoming image. The goal is to remove pages which will have little or no effect on performance.
Also, the ESS may not be able to provide the printer section 8, with the required image for printing because of a combination of the speed of the disk and a poorily cornpressed page. There may not be sufficient disk bandwidth to briing poorly compressed pages into memory in time for printing. Therefore, each job may incur a certain number of print pitch skips. A pitch skip is a time when the system is in full execution mode (charging and discharging of the photo-receptor) and yet a sheet of paper is not being imaged. Minimizing the number of print pitch skips is important in improving turn-around time and efficiently using the consumable of the machine. To minimize print pitch skips, the; minimum required resources and the optimal strategy to manage those limited resources need to be used.
With reference to the. flow chart, FIG. 7, a resource request for disk access to be completed by time T is illustrated at 230. It should be understood that multiple requests for multiple times can be handled. For example, a resource may ask that reads A and B be done by time T 1 and in the same request that reads C and D be completed by a different time T 2 . The resource manager then makes a determination whether or not the operations can be completed by the requested times as illustrated at 232. If a disk access can be completed within the requested times, then the disk access is scheduled as shown as 234.
However, if the requested disk access to be completed by a given time cannot be completed by the requested time as shown at 240, there is calculated a required delay time 242, 244 for requests B and D. In other words, if reads B and D cannot be completed by time T 1 and T 2 respectively, there will be a calculation of a necessary delay time equal to the difference between the a predicted completion time and the requested completion time. That is, if read B cannot be completed by T 1 , the Resource Manager predicts the appropriate completion time for read B which is the difference between the predicted completion time and the requested completion time or Delta T.
In a similar manner the request for read D to be completed at T 2 would be converted into a Delta T 2 which is the difference between the predicted completion time and the requested completion time of read D. Delta T 1 , and Delta T 2 are then compared to determine the maximum of the two delay times as illustrated at 246. This maximum delay time is then returned by the Resource Manager as shown at 248. This maximum delay time is converted by the Print Controller into a suitable machine delay or number of skipped pitches as illustrated at 250. The actual access operations are performed as shown at 252 with the appropriate number of skipped pitches. To implement these operations, the Resource Manager uses a timed disk operation queue. This operation queue includes disk access requests with associated start times. A start time is an absolute point in time in that the operation must be initiated in order to finish by the guaranteed time that was returned to the requesting resource. At the operations start time, the operation is removed from the queue. As operations are inserted into this queue, the Resource Manager predicts how long each of the operations will take to execute.
With reference to FIG. 8, in accordance with the present invention, there is illustrated a sequence of disk transfers along an axis representing time. Below the chart is a list of disk access requests waiting for available disk access time to complete their requests. The blocks marked 260, 262 and 264 are allocated disk access times to complete operations within a given period of time. These operation completion times have been guaranteed to the requesting resources. Blocks 266, 268, and 270 are disk access requests whose completion times are not guaranteed and are awaiting available disk access time to complete their requests.
When sufficient bandwidth is released by the completion of an operation, such as operation 260, 262 or 264 or a combination of operations for the completion of waiting operations, the Resource Manager 216 then selects the appropriate waiting operation for access. As illustrated, for example, operation 266 is moved into an allocated time slot with a suitable start time to complete the operation within the appropriate time. In general, the Resource Manager continually evaluates the priority of requests such as 266, 268 and 270, and also frees the memory upon the completion of some disk accesses to move requests from the waiting condition to the allocation and cornpletion condition. The Resource Manager eliminates the need for every resource to directly interact with one another for disk access time. Once a request is made, it can be determined at that time, if and when the request can be filled. Thus, various sources within the system know when the request will be filled without knowing or needing to know where the memory availability actually came from.
FIG. 9, is a flow chart illustrating the above feature. Block 272 is a request for disk bandwidth. At 274, the decision is made whether or not bandwidth is available within a required completion time. If not, the requesting resource or operation is put in or remains in the bandwidth request queue as illustrated at 276. If bandwidth is available, there is a calculation or determination of the available bandwidth at 276. At 278, there is a decision made if any operations in the queue can be completed with the available bandwidth. If not, the system must wait for additional available bandwidth as shown at 280. If operations or requests on the queue can be completed, the highest priority requester or operation is selected at 282 and the BW access is completed at 284.
While there has been illustrated and described what is at present considered to be a preferred embodiment of the present invention, it will be appreciated that numerous changes and modifications are likely to occur to those skilled in the art, and it is intended to cover in the appended claims all those changes and modifications which fall within the true spirit and scope of the present invention. | An electronic image processing apparatus comprising an electronic scanner and an electronic printer for forming an image, a controller for directing the operation of the image processing means, the controller including a mass memory device for storing data to be printed, random access memory, a printer control, and a Resource Manager for ensuring access to the random access memory for conveying data from the mass memory device to the printer via the random access memory, the Resource Manager including a mass memory device scheduler to provide printer access to the random access memory, the mass memory device scheduler having a reservation queue to reserve mass memory device access at predetermined times, delay means to determine that access to the mass memory device is invalid within a given time, and means to convey disk request operations to said reservation queue in order to provide guaranteed random access mernory at predetermined times. | 7 |
CROSS-REFERENCE TO RELATED APPLICATIONS
The contents of U.S. Pat. Nos. 6,722,202; 7,231,826; application Ser. No. 10/943,088, entitled “Magnetically Attracted Inspecting Apparatus and Method Using a Ball Bearing,” filed Sep. 16, 2004; application Ser. No. 10/943,135, entitled “Magnetically Attracted Inspecting Apparatus and Method Using a Fluid Bearing,” filed Sep. 16, 2004; and application Ser. No. 11/178,584, entitled “Ultrasonic Inspection Apparatus, System, and Method,” filed Jul. 11, 2005, are incorporated by reference.
FIELD OF THE INVENTION
The present invention relates generally to an apparatus, system, and method for inspecting a structure and, more particularly, to an apparatus, system, and method for non-destructive pulse echo ultrasonic inspection of a structure and inspection near holes and edges of the structure.
BACKGROUND
Non-destructive inspection (NDI) of structures involves thoroughly examining a structure without harming the structure or requiring its significant disassembly. Non-destructive inspection is typically preferred to avoid the schedule, labor, and costs associated with removal of a part for inspection, as well as avoidance of the potential for damaging the structure. Non-destructive inspection is advantageous for many applications in which a thorough inspection of the exterior and/or interior of a structure is required. For example, non-destructive inspection is commonly used in the aircraft industry to inspect aircraft structures for any type of internal or external damage to or defects (flaws) in the structure. Inspection may be performed during manufacturing or after the completed structure has been put into service, including field testing, to validate the integrity and fitness of the structure. In the field, access to interior surfaces of the structure is often restricted, requiring disassembly of the structure, introducing additional time and labor.
Among the structures that are routinely non-destructively tested are composite structures, such as composite sandwich structures and other adhesive bonded panels and assemblies and structures with contoured surfaces. These composite structures, and a shift toward lightweight composite and bonded materials such as using graphite materials, dictate that devices and processes are available to ensure structural integrity, production quality, and life-cycle support for safe and reliable use. As such, it is frequently desirable to inspect structures to identify any defects, such as cracks, discontinuities, voids, or porosity, which could adversely affect the performance of the structure. For example, typical defects in composite sandwich structures, generally made of one or more layers of lightweight honeycomb or foam core material with composite or metal skins bonded to each side of the core, include disbonds which occur at the interfaces between the core and the skin or between the core and a buried septum.
Various types of sensors may be used to perform non-destructive inspection. One or more sensors may move over the portion of the structure to be examined, and receive data regarding the structure. For example, a pulse-echo (PE), through transmission (TT), or shear wave sensor may be used to obtain ultrasonic data, such as for thickness gauging, detection of laminar defects and porosity, and/or crack detection in the structure. Resonance, pulse echo or mechanical impedance sensors are typically used to provide indications of voids or porosity, such as in adhesive bondlines of the structure. High resolution inspection of aircraft structure is commonly performed using semi-automated ultrasonic testing (UT) to provide a plan view image of the part or structure under inspection. While solid laminates and some composite structures are commonly inspected using one-sided pulse echo ultrasonic (PEU) testing, composite sandwich structures are commonly inspected using through-transmission ultrasonic (TTU) testing for high resolution inspection. In through-transmission ultrasonic inspection, ultrasonic sensors such as transducers, or a transducer and a receiver sensor, are positioned facing the other but contacting opposite sides of the structure. An ultrasonic signal is transmitted by at least one transducer, propagated through the structure, and received by the other transducer. Data acquired by sensors is typically processed and then presented to a user via a display as a graph of amplitude of the received signal. To increase the rate at which the inspection of a structure is conducted, a scanning system may include arrays of inspection sensors, i.e., arrays of transmitters and/or detectors. As such, the inspection of the structure can proceed more rapidly and efficiently, thereby reducing the costs associated with the inspection. However, it has traditionally not always been possible to perform continuous scanning of a structure with holes and off the edges of the structure. For example, inspection probes which contact and ride along the surface of the structure under inspection and are typically supported against the structure by the pull of gravity or by pressure exerted by a motion control system, referred to as part-riding probes, may fall through a hole in a structure or off the edge of the structure. Although a structure can be inspected in a manner to scan around holes, a second inspection method typically must be performed for inspecting the edges of the structure and edges defining holes in the structure. For example, a technician can manually scan around the edges of the structure and the edges of holes in a structure using a pulse-echo or through transmission ultrasonic hand probe.
Non-destructive inspection may be performed manually by technicians who typically move an appropriate sensor over the structure. Manual scanning requires a trained technician to move the sensor over all portions of the structure needing inspection. While manual scanning may be required around the edges of the structure and the edges of holes in a structure, manual scanning may also be employed for scanning the remainder of the structure.
Semi-automated inspection systems have been developed to overcome some of the shortcomings with manual inspection techniques. For example, the Mobile Automated Scanner (MAUS®) system is a mobile scanning system that generally employs a fixed frame and one or more automated scanning heads typically adapted for ultrasonic inspection. A MAUS system may be used with pulse-echo, shear wave, and through-transmission sensors. The fixed frame may be attached to a surface of a structure to be inspected by vacuum suction cups, magnets, or like affixation methods. Smaller MAUS systems may be portable units manually moved over the surface of a structure by a technician. However, for through-transmission ultrasonic inspection, a semi-automated inspection system requires access to both sides or surfaces of a structure which, at least in some circumstances, will be problematic, if not impossible, particularly for semi-automated systems that use a fixed frame for control of automated scan heads.
Automated inspection systems have also been developed to overcome the myriad of shortcomings with manual inspection techniques. For single sided inspection methods, such as pulse echo ultrasonic inspection, a single-arm robotic device, such as an R-2000iA™ series six-axis robot from FANUC Robotics of Rochester Hills, Mich., or an IRB 6600 robot from ABB Ltd. of Zurich, Switzerland, may be used to position and move a pulse echo ultrasonic inspection device. For through transmission inspection, a device such as the Automated Ultrasonic Scanning System (AUSS®) system may be used. The AUSS system has two robotically controlled probe arms that can be positioned proximate the opposed surfaces of the structure undergoing inspection with one probe arm moving an ultrasonic transmitter along one surface of the structure, and the other probe arm correspondingly moving an ultrasonic receiver along the opposed surface of the structure. Conventional automated scanning systems, such as the AUSS-X system, therefore require access to both sides or surfaces of a structure for through transmission inspection which, at least in some circumstances, will be problematic, if not impossible, particularly for very large or small structures. To maintain the transmitter and receiver in proper alignment and spacing with one another and with the structure undergoing inspection, the AUSS-X system has a complex positioning system that provides motion control in ten axes. The AUSS system can also perform pulse echo inspections, and simultaneous dual frequency inspections.
Many structures, however, incorporate holes through which a part-riding probe may fall through and edges over which a part-riding probe may fall off. Further, most structures require inspection of edges around the structure and defining holes in the structure. Accordingly, improved apparatus, systems, and methods for inspecting structures with holes and inspecting structures at edges are desired.
SUMMARY OF THE INVENTION
The present invention provides an improved apparatus, systems, and methods for inspecting a structure using an inspection probe that includes sled-like appendages, referred to herein as sled appendages or sleds, an axial braking system and a probe extension braking system. Inspection probes according to the present invention may be used in conjunction with a motion control system that both moves the probe over the structure for inspection and operates with the axial and extension braking systems for when the probe travels over holes or off edges of the structure. An inspection probe may also be used with an extension coupling device between the motion control system and the probe to press the probe against the structure for adjusting to changes in surface contours of the structure, rather than requiring the motion control system to make detailed changes in orientation and movement of the probe to adjust to changes in surface contours. Either the motion control system or a separate device, such as an extension coupling device, would be used to press the inspection probe against the structure so the inspection probe will ride across the structure on the sled appendages. Embodiments of the present invention combine the physical structure of the sled appendages with the axial braking system to fix the position of the sled appendages for traveling over holes or off an edge of the structure, including large holes or cut-outs in the structure which are also referred to herein as holes. Embodiments of the present invention can be used for various inspection applications but are particularly useful for inspection of structures that include holes and require inspection of the edges around the structure or defining a hole or have contoured surfaces. A probe will include one or more sensors, typically pulse echo ultrasonic transducers, possibly defining an array of pulse echo ultrasonic transducers. Such devices can be used for high resolution defect detection in structures of varying shapes and sizes. Embodiments of apparatus, systems, and methods of the present invention can be used for inspection of structures during manufacture or in-service. Further, embodiments of the present invention provide new inspection capabilities for non-destructive inspection of large and small structures, particularly including the edges of structures and structures with holes.
Embodiments of apparatus, systems, and methods of the present invention typically operate in array modes using an array of pulse echo ultrasonic transducers, thereby increasing inspection speed and efficiency while reducing cost. Apparatus, systems, and methods of the present invention are also capable of operating with a single or a plurality of pulse echo ultrasonic transducers.
For continuous scanning applications, embodiments of apparatus, systems, and methods of the present invention permit the probe to contact and ride along the surface of the structure using one or more sled appendages, thereby reducing the necessary sophistication of a motion control system that is typically required by conventional scanning systems to maintain the probe in a predefined orientation and predefined position with respect to the surface of the structure. By allowing the probe to ride across the structure, the motion control system, or a separate device such as an extension coupler, only needs to press the probe against the structure, but does not need to know the surface contours of the structure because the act of pressing the probe against the surface combined with the sled appendages having freedom of motion and the axial motion of the probe compensate for surface contours. In addition to sled appendages, the probe may also use contact members to support the probes against the respective surfaces of the structure, such as roller bearings along the bottom of the sled appendages. The sled appendages are rotatably connected to permit freedom of motion of the sled appendages for riding along contoured surfaces. Contact with the surface ensures consistent orientation of transducers with respect to the structure for pulse echo ultrasonic inspection. Contact with the surface also permits accurate position measurement of the inspection device during continuous scanning, such as keeping an optical or positional encoder in physical and/or visual contact with the surface of the structure under inspection. Contact with the surface also permits the probe to disperse a couplant between the surface of the structure and the pulse echo ultrasonic transducers. Where a couplant is used, a probe may also include a bubbler shoe that disperses the couplant around each pulse echo ultrasonic transducer to independently couple the signal from each transducer to the surface of the part. By individually coupling each transducer to the surface of the part, the bubbler shoe compensates for when the probe travels over a hole or off an edge of the structure where all of the transducers are not over the surface of the structure. In such a manner, only the probes over the hole or off the edge of the structure will lose the coupling with the surface, but the transducers remaining over the surface of the structure will continue to be independently coupled.
The axial and extension braking systems of a probe are used to fix the position of the sled appendages for traveling over holes or off an edge of the structure. Thus, for continuous scanning applications, the probe contacts and rides along the surface of the structure on the sled appendages, but as the probe approaches a hole or edge, the axial and extension braking systems, either using data of the hole and edge positions for the structure and the current location of the probe or using braking signals from a motion control system, fixes the current position of the sled appendages for traveling over the hole or off an edge and again contacting and riding along the surface of the structure after passing the hole or retracting from the edge at which time the axial braking system releases to permit the sled appendages to follow the contour of the surface of the structure. An axial braking system of an embodiment of a probe of the present invention can operate in more than one axis, and typically operates in two perpendicular axes referred to herein as the x-axis perpendicular to the distal length of the sled appendages to control the front-to-back tilt, or pitch, of the sled appendages and the y-axis parallel to the distal length of the sled appendages to control the side-to-side slant, or roll, of the sled appendages.
According to one aspect of the present invention, an apparatus, system, and method for non-destructive inspection of a structure includes a probe which is configured for traveling over a surface of the structure along sled appendages and using an axial braking system for traveling over holes and off edges of the structure. The probe includes at least one pulse echo ultrasonic transducer. A plurality of pulse echo ultrasonic transducers may be arranged in an array for faster and more complete scanning of the structure. If a couplant is used to couple the transducers to the surface of the structure, the probe may include a bubbler shoe to individually couple each transducer to the surface of the structure to prevent loss of coupling of transducers remaining over the surface of the structure when one or more transducers are over a hole or off an edge. The probe may also include a visual inspection sensor for providing position or optical information related to the location of the probe or transducers thereof.
According to another aspect of the present invention, a method may include providing a probe with at least one pulse echo ultrasonic transducer, at least one sled appendage for contacting a surface of a structure, and axial and extension braking systems; transmitting pulse echo ultrasonic signals from the transducer into the structure; receiving pulse echo ultrasonic signals at the transducer from the structure; and fixing the position of the sled for scanning a portion of the structure where only a portion of the probe is over the surface of the structure.
BRIEF DESCRIPTION OF THE DRAWING(S)
FIG. 1 is a schematic diagram of an embodiment of an inspection apparatus of the present invention.
FIG. 2 is another view of the schematic diagram of the inspection apparatus of FIG. 1 .
FIG. 3A is a schematic diagram of another embodiment of an inspection apparatus of the present invention.
FIG. 3B is a top plan view of the inspection apparatus of FIG. 3A .
FIG. 3C is a top plan view of the bubbler shoe of the inspection apparatus of FIG. 3A .
FIG. 4 is a cross-section of a schematic diagram of yet another embodiment of an inspection apparatus of the present invention.
FIG. 5 is a block diagram of an embodiment of an inspection system of the present invention.
DETAILED DESCRIPTION
The present invention will be described more fully with reference to the accompanying drawings. Some, but not all, embodiments of the invention are shown. The invention may be embodied in many different forms and should not be construed as limited to the described embodiments. Like numbers and variables refer to like elements and parameters throughout the drawings.
The term “holes” refers to holes of varying sizes in a structure, including features described as “cut-outs” in the structure. The term “edges” refers generally to the sides of the structure, but also includes reference to the perimeter of holes, particularly large holes or cut-outs through which a conventional part-riding probe might fall through. Thus, holes may be described as having edges, and the term edges is inclusive of both an external perimeter of a structure and perimeters of internal holes in the structure. Although being characteristically different, for purposes of the present invention holes and edges differ primarily by the manner in which a probe of the present invention operates near these features. For example, the probe typically travels over a hole or cut-out but travels off an edge of the structure, and possibly returning over the structure from an edge. Further, while in some instances in the description below using only one of the two terms holes and edges may be sufficient, typically both terms are used to emphasize that the described function or operation applies to both holes in the structure and edges of the structure, and not merely one of these features.
The term “rotatably” refers to a characteristic of angular motion in at least one plane, and typically only one plane as may be defined by a connection about an axis-line as described in the examples below. However, a rotatable connection may also be defined by a connection that provides angular motion in more than one plane, such as a ball-and-socket joint connection that permits motion of the joint without permitting rotation in at least one plane, such as to provide freedom of motion to pitch and roll, but not yaw.
The present invention provides apparatus and methods for an ultrasonic array probe for inspecting a structure while riding on a surface of the structure. The probe has the ability to travel over holes and off edges of the structure during inspection. Typically a probe according to the present invention would be moved over a structure by a motion control system, such as an R-2000iA™ series six-axis robot from FANUC Robotics, an IRB6600 robot from ABB, or similar automated robotic motion control system, and possibly also using an extension coupler to compensate for surface contours rather than requiring the motion control system to compensate for surface contours. An example motion control system with an extension coupler for manipulating an inspection apparatus of the present invention is described in application Ser. No. 11/178,584, entitled “Ultrasonic Inspection Apparatus, System, and Method,” which is incorporated by reference. The combination of sled appendages and an axial braking system provide the configuration for the probe to be able to travel over holes and off edges of the structure during inspection. By comparison, conventional part-riding probes, probes which contact and ride along the surface of the structure under inspection, may fall through a large hole or off the side of a part rather than having the ability to travel over holes and off the edge of a part for inspection. Using conventional part-riding probes, a structure typically is scanned in a manner to go around holes and to not inspect near edges, leaving the edges of the structure to be inspected by a second inspection method, such as by a technician using a manual pulse echo scanning device. Sled appendages, or sleds, of a probe according to the present invention are linear extensions rotatably attached to the bottom of the probe and upon which the probe rides over a surface of the structure. An axial braking system according to the present invention operates to temporarily fix the current positions of the sled appendages to maintain those positions while the probe travels over a hole or off an edge of the structure. An axial braking system may operate in one or more axes. For example, the braking system may lock simply in an x-axis, in both x- and y-axes, or in x-, y-, and z-axes. The axial braking system fixes the position of the sled appendages by locking the axes of motion of the sled appendages before traveling over a hole or off an edge of the structure.
Although in some instances the length of sled appendages may be sufficient to pass over a small hole without needing to use the axial braking system of the probe, the combination of sled appendages and axial braking system are generally provided and used for instances when the probe would otherwise fall through a large hole or off an edge of a structure like a conventional part-riding probe were it not for the operation of the axial braking system to maintain the position of the sled appendages while the probe moves over a hole or off an edge of the structure. Further, by using a probe according to the present invention, a motion control system does not need to maintain or know the precise shape or contour of the structure, but merely the location of holes and edges of the structure so the axial braking system can fix the position of the sled appendages before the probe is passed over a hole or off an edge of the part. Further, although the inspection apparatus described and depicted herein includes two sled appendages located on opposing sides of the inspection apparatus, and an inspection apparatus according to the present invention typically includes two sled appendages, an inspection apparatus of an embodiment of the present invention might include only a single sled appendage such as a sled appendage with a broad surface width for providing side-to-side balance to the inspection apparatus. Alternative embodiments of an inspection apparatus may include a plurality of sled appendages extending below the inspection apparatus and/or to the sides of the inspection apparatus.
A probe may also include a bubbler shoe. A bubbler shoe according to the present invention provides a couplant around each transducer for individually coupling each transducer of the probe that remain over the structure for inspection even when other transducers may be over holes or off an edge of the structure. By comparison, conventional coupling shoes typically provide a cavity that surrounds all of the transducers to act as a single couplant for all of the transducers. Thus, if a conventional probe travels over a large hole or off an edge of the part, the water cavity will empty and the ultrasonic signals of all of the transducers may be lost or will be degraded due to the lack of coupling between the structure and the transducers. However, when using a bubbler shoe of an embodiment of the present invention, only the transducers that are over the hole or off the edge of the structure may lose coupling for ultrasonic signals while the transducers remaining over the structure retain the coupling provided by the bubbler shoe.
FIGS. 1 and 2 are schematic diagrams of an embodiment of an inspection apparatus according to the present invention, also generally referred to as a probe or inspection probe. The inspection apparatus 10 includes two sled appendages 12 , 13 located on opposite sides of the inspection apparatus 10 . The sled appendages 12 , 13 are rotatably attached to a frame member 14 of the inspection apparatus 10 about a first axis 24 defining a first direction of motion for the sled appendages 12 , 13 , also referred to as an x-axis, front-to-back tilt axis, or pitch axis. The frame of the inspection apparatus 10 also includes a second frame member 16 which is rotatably connected to the first frame member 14 about a second axis 26 defining a second direction of motion for the sled appendages 12 , 13 , also referred to as a y-axis, side-to-side slant axis, or roll axis. By having two rotational axes, the sled appendages 12 , 13 are capable of rotating in at least two directions of motion with respect to a motion control system connected to the inspection apparatus 10 , such as by way of an attachment at the opening 18 and securing screws 19 , to compensate for surface variations of the structure, such as shape and contour characteristics of the surface. Further, because as described below, a transducer holder or bubbler shoe for an inspection apparatus of the present invention is connected to sled appendages, rather than the frame, the transducers maintain the same position and orientation as achieved by the sled appendages, thereby providing the transducers a consistent orientation with respect to the surface of the structure over which the inspection apparatus rides on the sled appendages. Maintaining a consistent orientation, distance and angle, of the transducers with respect to the surface of the structure ensures consistent quality of inspection by the transducers.
At least one of the sled appendages 12 , 13 includes an upper portion 22 , 23 that functions as a stationary brake plate against which a brake disc 30 of the axial braking system can be applied to fix the position of the sled appendage about the first axis of motion 24 . An axial braking system of an embodiment of the present invention may also include a pneumatic brake cylinder 32 with an extendable piston arm 34 to which a brake disc 30 is attached at the distal end of the extendable piston arm 34 protruding from the brake cylinder 32 . A brake cylinder 32 may be activated by any conventional method, such as by compressing a fluid, typically air, through a supply line 38 into a valve 36 attached to the brake cylinder 32 . When the brake mechanism is activated, the compression of fluid causes a piston inside the brake cylinder 32 and attached to the distal end of the extendable piston arm 34 inside the brake cylinder 32 to force the extendable piston arm 34 out of the brake cylinder 32 to force the brake disc 30 to press against the stationary brake plate 22 , 23 of one or more sled appendages 12 , 13 .
To fix the position of the sled appendages in the second axis of motion 26 , a second brake plate 28 may be affixed to the first frame member 14 to permit a second brake mechanism 40 , 42 , 44 , 46 , 48 , to engage the second stationary brake plate 28 in the same manner that the first brake mechanism 30 , 32 , 34 , 36 , 38 engages the first stationary brake plate 22 , 23 to fix the position of the sled appendages 12 , 13 about the first axis of motion 24 . The first frame member 14 may include a vertical support member 15 connected to the second stationary brake plate 28 to provide stability between the first frame member 14 and the second stationary brake plate 28 , such as when a brake disc 40 is pressed against the second stationary brake plate 28 to fix the position of the sled appendages in the second axis of motion 26 . An axial braking system of an alternative embodiment may also include a brake mechanism in a third direction of motion, such as a vertical z-axis with respect to the surface of the structure, and may be incorporated into an attachment to a motion control system.
To improve braking capabilities of a braking system, brake discs and/or stationary brake plates may be coated with or include an attached layer of material, such as being coated with rubber, to cause increased friction between a brake disc and stationary brake plate for fixing the positions of sled appendages and preventing slippage of the positions of the sled appendages.
The inspection apparatus 10 includes at least one pulse echo ultrasonic transducer 50 . If not using a couplant between the transducers 50 of the inspection apparatus 10 and the structure, a transducer holder may be attached to the sled appendages 12 , 13 to support the transducers 50 , such as supported in an array where a plurality of transducers are used to increase the inspection coverage area. As mentioned above, by attaching the transducer holder, or bubbler shoe as described below, to the sled appendages 12 , 13 the transducer holder and transducers 50 supported thereby also maintain constant orientation with the surface of the structure over which the inspection apparatus 10 rides because the inspection apparatus 10 rides over the surface of the structure on the sled appendages 12 , 13 . Because inspection of a structure typically requires ensuring that the transducers maintain constant orientation, distance and angle, with respect to the surface of the structure, attaching a transducer holder, or bubbler shoe, to sled appendages ensures that the transducer holder, or bubbler shoe, and transducers supported thereby also maintain constant orientation with respect to the surface of the structure for consistent quality of inspection by the transducers.
If a couplant is to be used to couple the ultrasonic signals from the transducers 50 into the structure and reflected from the structure back to the transducers 50 , a bubbler shoe 60 may be incorporated into the inspection apparatus 10 . The bubbler shoe 60 individually couples each transducer 50 rather than using a single cavity to couple all of the transducers 50 . A bubbler shoe may include a top (or first) layer 62 that includes holes 64 to permit access to the transducers 50 , such as by the transducer protruding through the holes 64 in the top layer 62 or by permitting a wired connection through the holes 64 in the top layer 62 for communication with the transducers 50 . The top layer 62 may also include one or more fluid inlets 68 , 69 through which a couplant may be injected into the bubbler shoe 60 . The bubbler shoe 60 may also include a bottom (or second) layer that, together with the top layer 62 , define a cavity through which a couplant from the fluid inlet 68 , 69 can flow to individually couple each transducer 50 . By way of example, such cavities may be a single open cavity providing a fluid path to each transducer or may be a cavity structured with a manifold configuration whereby the couplant passes into separate subcavities that lead to the individual transducers. The bottom layer includes holes through which the couplant passes to couple the transmission of ultrasonic signals from the transducers 50 . The transducers 50 may pass through the holes in the bottom layer, may terminate inside the cavity, or may terminate within the bottom layer.
FIG. 3A is a schematic diagram of another embodiment of an inspection apparatus of the present invention. FIG. 3B is a top plan view of the inspection apparatus of FIG. 3A . FIG. 3C is a top plan view of the bubbler shoe of the inspection apparatus of FIG. 3A . The inspection apparatus 310 of FIGS. 3A , 3 B, and 3 C differs from an inspection apparatus 10 of FIGS. 1 and 2 in that the inspection apparatus 310 of FIGS. 3A , 3 B, and 3 C provides only one axis of motion 324 for the sled appendages 312 , 313 , while the inspection apparatus 10 of FIGS. 1 and 2 provides two axes of motion 24 , 26 for the sled appendages 12 , 13 . Although a bubbler shoe 60 with a transducer array is present in the inspection apparatus 10 of FIGS. 1 and 2 , FIGS. 3A , 3 B, and 3 C clearly show an example configuration for an array of transducers in the bubbler shoe 360 of the inspection apparatus 310 . While the internal construction of the bubbler shoe 360 is visible to some extent in FIG. 3A , FIG. 4 clearly shows an example internal construction of another bubbler shoe 460 .
FIG. 4 is a cross-section of a schematic diagram of yet another embodiment of an inspection apparatus of the present invention. The cross-section represents an approximate mid-point through a first axis of rotation 424 corresponding to the front-back tilt of the sled appendages 412 , 413 . The cross-sectional view shows the internal structure of one embodiment of a bubbler shoe 460 for individually coupling each transducer 450 according to the present invention. The bubbler shoe 460 includes a top layer 462 and a bottom layer 464 configured together to form a cavity 461 into which a couplant is injected for being dispersing about the cavity 461 and, after filling the cavity 461 , being evenly dispersed around each of the transducers 450 to couple the ultrasonic signals from the transducers 450 to the structure. A fluid couplant path 472 passes through a supply line 470 into and through a fluid inlet 486 into the bubbler shoe 460 . The couplant path continues to disperse throughout the cavity 461 as indicated by the fluid couplant path 478 . The ejection of the couplant from the cavity 461 of the bubbler shoe 460 around each of the transducers 450 is indicated by fluid couplant paths 476 . Typically water may be used for a couplant, but other fluids may be used, including a gas, such as air.
The cross-section of the inspection apparatus of FIG. 4 also shows how the bubbler shoe 460 may be connected to the sled appendages 412 , 413 to maintain constant orientation with respect to the structure by the bubbler shoe 460 and transducers 450 supported thereby. The connection 474 between the sled appendages 412 , 413 and the bottom layer 464 of the bubbler shoe 460 provides a non-rotational connection between the bubbler shoe 460 and the sled appendages 412 , 413 . By comparison to the first axis of motion 424 , the connection 474 is not a rotational axis that provides a direction of motion but is fixed to provide the same orientation with respect to the structure that the sled appendages 412 , 413 have to the bubbler shoe 460 and transducers 450 supported thereby.
FIG. 5 is a block diagram of an inspection system of the present invention. The block diagram shows communication between a motion control system 512 and an axial braking system 514 . In addition, electronic data 510 representing the configuration of the structure under inspection, including position information for holes in edges of the structure, is provided to the motion control system 512 . An alternative embodiment for an inspection system may include an axial braking system that incorporates hardware and software to interpret the position of the inspection apparatus with respect to holes and edges of the structure, referred to as a smart axial braking system. For example, a smart axial braking system may include some form of a position encoder or positioning system that operates to identify the location of the inspection apparatus with respect to the structure and electronic data representing the configuration of the structure, such as the electronic data 510 provided to the motion control system in the embodiment shown in FIG. 5 .
The axial braking system 514 may be activated based on data provided by the motion control system 512 . For example, the motion control system 512 may incorporate software that interprets the position of the inspection apparatus with respect to holes in edges of the structure and indicate to the axial braking system 514 when to activate the braking mechanisms on an inspection apparatus to fix the positions of sled appendages on the inspection apparatus and when to deactivate the braking mechanisms. For example, when the motion control system 512 identifies that the inspection apparatus is about to travel over a hole, the motion control system 512 can communicate to the axial braking system 514 to fix the current position of the sled appendages for while the inspection apparatus travels over the hole. When the motion control system 512 determines that the inspection apparatus has passed over the hole, the motion control system 512 may communicate to the axial braking system 514 to release the sled appendages so they may continue to ride along and follow the contoured surface of the structure. For example, a solenoid actuated pneumatic switch of the axial braking system 514 may activate to apply pressure to a pneumatic brake cylinder to extend brake discs against stationary brake plates on the sled appendages. The activation of the solenoid actuated pneumatic switch may be controlled by output signals provided by the motion control system 512 to indicate to the axial braking system 514 to fix the positions of the sled appendages.
Alternatively, the motion control system 512 may provide location data of the inspection apparatus with respect to a structure being inspected to the axial braking system 514 , and the axial braking system 514 may use the location data, in addition to electronic data 510 representing the configuration of the structure either provided through the motion control system 512 or directly to the axial braking system 514 , to determine when the axial braking system 514 should activate braking mechanics on the inspection apparatus to fit the positions of sled appendages, such as before traveling over a hole or off an edge of the structure.
The invention should not be limited to the specific disclosed embodiments. Specific terms are used in a generic and descriptive sense only and not for purposes of limitation. | Improved apparatus, systems, and methods for inspecting a structure are provided that use a probe with sled appendages and an axial braking system. The probe uses pulse echo ultrasonic signals to inspect the structure. The sled appendages permit the probe to contact and ride along the surface of the structure and are rotatably connected and curved away from the surface of the structure to compensate for contoured surfaces and inspection around holes and edges. The axial braking system, in coordination with a motion control system moving the probe, fixes the positions of the sled appendages just before the probe travels over a hole or off an edge of the structure to prevent the probe from falling through the hole or off an edge and to permit the probe to return to the surface of the structure to continue inspection of the structure. | 6 |
BACKGROUND OF THE INVENTION
This invention is directed to the sizing of spun cotton yarns, particularly dyed spun cotton yarns, by treatment of the yarns prior to weaving with a low molecular weight polyacrylamide solution-polymerized polymer.
The use of variuous compounds as sizing agents for warp yarns to prevent breakage of the yarn during weaving is well known. The sizing agents are placed upon the warp yarns prior to weaving to provide strength and protection to the yarns from abrasion. Traditional sizing agents for cotton-containing yarns have generally included film formers such as starch, derivatives of starch, polyvinyl alcohol, polyester resins, waxes, acrylic polymers and copolymers and their salts, wetting agents, antistatic agents, and the like. Current commercial sizes are predominantly based upon starch in combination with one or more of polyvinyl alcohol, polyester resins, acrylic copolymer resins, and waxes.
A good sizing agent is one which will form a film with sufficient strength to provide protection to the yarn being sized but not so strong that the yarn will break before the size film. This is particularly important as yarns are generally sized in a size box, then the water removed on steam cans and the yarns form a sheet. Then this sheet of yarns is run across bust rods to break the sheet back into individual yarns for weaving.
Previous attempts to utilize polyacrylamide homopolymers as sizing agents have not been successful. For example, U.S. Pat. No. 4,515,855 claims the use of acrylamide copolymers and multipolymers with at least one monomeric compound containing a hydrophobic polymerizable reactive vinyl or vinylidene group but asserts that homopolymers of acrylamide impart only minor protection to fibers during weaving. Example 11 pads a polyacrylamide polymer solution unto single-end 100% untreated cotton yarns. No indication of the type of polyacrylamide polymer nor its molecular weight are provided. Evaluation of the polyacrylamide padded yarns indicate little difference in performance vs. starch alone and substantially inferior performance as compared to the claimed copolymers and multipolymers. U.S. Pat. No. 4,410,588 contains a similar statement on acrylamide homopolymers but also contains no details thereon.
Since the prior sizing agents have not been completely adequate for use in processing spun yarns, it is an object of the present invention to overcome certain of the deficiencies of the prior sizes, particularly in the processing of dyed spun cotton yarns, and more particularly when such yarns are to be overdyed.
Furthermore, with the increasing levels of both general environmental concern and garment processing in the denim industry, e.g. stone washing, pre-washing, and the like, it is an object of the present invention to utilize a more readily degradable sizing agent, i.e. one which has a reduced biological oxygen demand (BOD) and a reduced chemical oxygen demand (COD).
It is a still further object of the invention to develop an effective non-ionic sizing agent which will permit the utilization of cationic fixing agents such as polyamine and polyamide polymers.
It is a still further object of the invention to develop a sizing agent which does not get tacky or sticky in the presence of the very high moisture levels which are commonly present in weaving rooms.
These and still further objects will be apparent from the detailed description of the invention which follows.
SUMMARY OF THE INVENTION
Accordingly, the present invention is directed to a method of sizing a spun cotton yarn substrate by applying to the substrate an aqueous solution consisting essentially of a polyacrylamide polymer which has a viscosity of about 400 to 900 cps at 20% solids and thereafter drying the treated substrate, said polymer being applied in an amount sufficient to impart a high order of abrasion resistance to the yarn while being capable of being removed from the yarn by aqueous washing, preferably to increase the weaving efficiency of the yarn substrate by at least about 3% as compared to conventional starch sizing agent compositions. When the spun cotton yarn substrate is a dyed spun yarn, suitable such amounts are generally about 4 to 8 wt %, based on the weight of the yarn. When the spun cotton yarn substrates are towel pile yarns, suitable such amounts are about 2.25 to 4 wt %. Both insufficient and excessive amounts of size have been found to reduce the weaving efficiency to below the level obtained by following the present invention.
As a result of this invention, weaving efficiency is substantially increased while simultaneously reducing the amount of sizing agent required. This economical treatment produces a sized yarn which is also more environmentally friendly than previous sized yarns in view of the very low BOD and COD values of the resulting fabric.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
The present invention involves the use of an aqueous solution consisting essentially of a narrow class of non-ionic polyacrylamide homopolymers as a sizing agent for spun cotton yarns.
Suitable polyacrylamide homopolymers for use herein are those which have been produced by a solution polymerization procedure, as opposed to a bulk or suspension or emulsion or inverse emulsion polymerization technique. The solution polymerized polyacrylamide homopolymers have a low molecular weight as evidenced by a viscosity of a 20 wt % aqueous solution thereof being only about 400 to about 900 cps, preferably about 500 to about 800 cps, as determined by a Brookfield RVT Viscometer at 25° C. using spindle #3 at 50 RPM. It is believed that this viscosity corresponds to a molecular weight in the range of about 30,000 to about 180,000 daltons. Care should be taken to prevent hydrolysis of the polyacrylamide polymer as the presence of acid groups has been found to be deleterious to the performance of the sizing agent, particularly in the high moisture levels commonly found in weaving rooms to facilitate the weaving process.
Any conventional acrylamide solution polymerization technique may be used to prepare the solution polyacrylamide polymers used herein. Generally, acrylamide monomer is polymerized in an aqueous medium, under an inert atmosphere, and in the presence of a catalytic amount of a free-radical source such as ammonium persulfate, ammonium persulfate and sodium bisulfite, and the like. The reaction mixture is stirred under the inert atmosphere until the polymerization is completed.
The resulting product is a slightly viscous solution which, depending upon its solids content, may be directly used in the present invention or may need to be diluted to a lower solids level. A particularly suitable such polymer is available from Callaway Chemical Company as Callaway 4600. Although it is possible to incorporate starch, polyvinyl alcohol, waxes, and other sizing agents along with the polyacrylamide homopolymer in a sizing composition, such is not preferred. Similarly, other conventional sizing additives, such as binders, lubricants, plasticizers, and the like, may be added but are also not preferred. Most preferably, the cotton yarns are sized with a simple polyacrylamide solution polymer in water.
The solution polyacrylamide polymer is applied to spun cotton yarn in an amount sufficient to impart a high order of abrasion resistance to the yarn while being capable of being removed from the yarn by aqueous washing, preferably in an amount to increase the weaving efficiency of the yarn substrate by at least about 3% as compared to a conventionally used starch sizing agent. The standard is determined by averaging the weaving efficiency of all of the looms preparing the same type product at the time a mill trial is performed with the sizing agent of this invention. Generally such conventional sizing agents include starch often in combination with one or more of polyvinyl alcohol, acrylic binders, waxes, acrylic copolymers, and the like. When the spun cotton yarn substrate is a dyed spun yarn, a suitable such amount is about 4 to 8 wt %, based on the weight of the yarn. When the spun cotton yarn substrate is undyed towel pile yarns, a suitable such amount is about 2.25 to 4 wt %. Both insufficient amounts of size have been found to reduce the weaving efficiency to below the at least about 3% increase obtained by following the present invention. Excessive amounts of size which may also reduce weaving efficiency have also been found to deleteriously effect the performance of the constructed fabric, in some cases because of increased lubrication and removal efficiency as compared to current sized fabrics during garment processing.
The application of the solution polyacrylamide polymer to the spun cotton yarns is by conventional padding, spraying, knife coating, and the like. Preferably, the yarn is beamed on a reel and run through a size box and squeeze rollers set to deposit the desired level of sizing agent solids. Thereafter, the treated yarns are dried, routinely by heating to an elevated temperature for a short period of time on steam cans. The resulting yarns are in the form of a sheet which is run across bust rods to break the yarn sheet back into individual yarns for weaving.
Suitable cotton yarns for use herein are spun yarns which include ring spun, open-end, and air-jet yarns. The spun yarns may be cotton or a blend of cotton and some other fiber.
The process of this invention produces a size coating on spun cotton yarns which is characterized by easy removal in subsequent washing. More particularly, the effluent from that washing is far less detrimental to the environment than current commercial sizing products. The approximate biological oxygen demand and the chemical oxygen demand for the solution polyacrylamide homopolymers used herein vs. conventional sizes are as follows:
TABLE I______________________________________Sizing agent BOD (mg/l) COD (mg/l)______________________________________Solution polyacrylamide 8,000 160,000-421,000Starch 650,000 1,500,000Polyvinyl alcohol 16,000 70,400-720,000______________________________________
The treated textile substrates are further characterized by generally requiring less total sizing agent then is currently commercially used. For example, with traditional size formulations used with a dyed yarn, about 9-14 wt % size is commonly used to give a sufficient degree of protection during weaving. Superior results in actual field trials with the present invention have been obtained at only 4-8 wt % solution polyacrylamide polymer. Similarly, with traditional size formulations used with undyed towel pile yarn, about 5-7 wt % size is commonly used while the present invention enables the use of about 2.25-4 wt % size.
When the spun yarn substrate has been pre-dyed, as is common in denim processing, the fabric produced after weaving and/or the garments produced therefrom can be directly overdyed without the need for prior removal of the sizing agent. Of course, the size may be removed prior to overdyeing.
The following examples are illustrative of the process of the present invention and not in limitation thereof. All parts and percents are by weight unless otherwise specified.
EXAMPLE 1
190.5 g of aqueous acrylamide (52.5% real solids) was added to 300.0 g water in a suitable reaction vessel with sufficient agitation to create a distinct vortex. Nitrogen sparging was begun and a solution of 0.36 g sodium hypophosphite in 5.1 g water was charged into the reaction vessel. The reaction mixture was heated slightly to a temperature of 23°-26° C. and then the nitrogen was changed from a sparge to a blanket. 0.96 g of ammonium persulfate was added and within 20 seconds a premixed solution of 0.14 g sodium metabisulfite in 1.2 g water was also added. Thereafter the reaction vessel was sealed off and the polymerization reaction occurred. Adequate cooling was used to maintain the reaction temperature between 80° and 90° C. After the exotherm subsided, a solution of 0.02 g sodium metabisulfite in 0.25 g water was added, the cooling was turned off, and the reaction mixture held for 45 minutes. After cooling to 50°-55° C. the pH was adjusted to 5-7 with caustic soda and the solution diluted to 20 wt % solids. The resulting dilute polymer solution had a viscosity of 650 centipoise as determined by Brookfield RVT Viscometer, spindle no. 3, 50 RPM, 25° C.
EXAMPLE 2
A field trial of the process of the present invention was performed by mixing 600 pounds of a diluted solution polyacrylamide polymer prepared as described in Example 1 with 190 gallons of water and adding it to a size box. The size mix was not cooked but was heated to 200°-205° F. (93°-96°C.) in a size box during the application. Sulfur black dyed open-end yarn (6's), 100% cotton, 143/4 oz. fabric, was passed through the size box and then was squeezed with rollers to add on 5.3% of solution polyacrylamide polymer. After drying on steam cans, the resulting sheet of yarns was run across bust rods (slasher) to break the sheet back into individual yarns for weaving.
No problems occurred on the slasher and a weaving trial was performed. At the same time as the trial, the mill was running 40 other looms of the same spun yarn which had been sized in accordance with the mill's conventional starch based sizing composition for this yarn. The conventional composition was a mixture of 350 pounds starch, 86 pounds acrylic emulsion polymer, and 160 gallons water. The weaving efficiency of the loom utilizing the sizing agent of this invention was 94.5%. The average weaving efficiency of the conventionally sized looms was 91.4%. The weaving efficiency is determined by dividing the number of theoretical picks into the actual number of picks run (a pick occurs every time a filling yarn is inserted into the fabric). When a yarn breaks the loom stops, reducing the number of picks run per unit time. Types of yarn breaks are characterized and counted to give a loom efficiency and also to determine the level of defects (breaks) which are warp-related and which are fill-related (fill yarn contains no size).
Portions of the fabric produced in accordance with the present invention and the fabric produced with the conventional starch-based size were subjected to overdyeing. The fabric produced by this invention was overdyed without desizing. The conventional starch sized fabric was desized before overdyeing. The invention fabric met the dye shade standard and showed no size spots (defects in the overdyed fabric). The desized conventional fabric was overdyed in accordance with convention practice and, although found to meet the dye shade standard, contained size spots (defects) because of incomplete removal of size.
EXAMPLE 3
The procedure of Example 2 was again repeated except that (i) the yarn sized was 6's indigo dyed, 100% cotton ring spun yarn 143/4°ounce fabric, (ii) 575 pounds of the 20% polyacrylamide polymer solution was initially blended with 211 gallons of water, (iii) the polyacrylamide solution polymer add on was 4.9%, and (iv) the size mix was not cooked or heated but rather was run at ambient temperature.
The results of a weaving trial in comparison with 200 looms of conventionally starch-sized yarn composed of 300 pounds starch, 40 pounds polyvinyl alcohol, 20 pounds of paste wax, and 206 gallons water. The add-on was a standard 12%. The trial showed that the weaving efficiency of the yarn treated in accordance with the present invention was 99.3% while the average of the conventional starch-treated yarns was only 94.0%.
EXAMPLE 4
The procedure of Example 2 was again repeated except that (i) the yarn sized was 6's indigo dyed open end yarn, 100% cotton 12 ounce fabric, (ii) 300 pounds of the 20% polyacrylamide polymer solution was initially blended with 95 gallons of water, and (iii) the polyacrylamide solution polymer add on was 7.1%.
The results of a weaving trial in comparison with 100 looms of conventionally sized yarn composed of 250 pounds of starch, 50 pounds acrylic emulsion polymer, 25 pounds of wax, and 230 gallons of water, showed that the weaving efficiency of the yarn treated in accordance with the present invention was 92% while the average of the conventionally treated yarns was only 88%.
COMPARATIVE EXAMPLE A
The procedure of Example 2 was again repeated except that (i) the yarn sized was 6's indigo dyed open-end yarn, 100% cotton 143/4°ounce fabric, (ii) 660 pounds of the 20% polyacrylamide polymer solution was initially blended with 140 gallons of water, and (iii) the polyacrylamide solution polymer add on was 11.64%.
The results of a weaving trial in comparison with 100 looms of conventionally sized yarn composed of 250 pounds of starch, 50 pounds acrylic emulsion polymer, 25 pounds of wax, and 230 gallons of water, showed that the weaving efficiency of the yarn treated with the solution polyacrylamide polymer was substantially the same as that of the conventionally treated yarn, i.e. no difference was found.
When the resulting fabric with the solution polyacrylamide polymer size on it was garment washed and bleached with hypochlorite, the fabric appeared lighter and more varied than the fabric from the same dye set that had been conventionally-sized.
COMPARATIVE EXAMPLE B
The procedure of Example 2 was again repeated except that (i) the yarn sized was 6's indigo dyed open-end denim, (ii) 500 pounds of the 20% polyacrylamide polymer solution was initially blended with 300 gallons of water, and (iii) the polyacrylamide solution polymer add on was 3.3%.
The results of a weaving trial in comparison with 125 looms of conventionally sized yarn composed of 450 pounds starch, 100 pounds of a dry blend believed to be a mixture of wax, urea, and polyvinyl alcohol, and 330 gallons water, showed that the yarn treated with the polyacrylamide solution polymer did not weave well because the warp was too soft to protect the yarn.
COMPARATIVE EXAMPLE C
The basic procedure of Example 2 was again repeated except that (i) the size was added to undyed towel pile yarns which were 16's open-end yarns, (ii) 250 pounds of the 20% polyacrylamide polymer solution was initially blended with 300 gallons of water, and (iii) the polyacrylamide solution polymer add on was 1.52%.
A weaving trial was performed. Although the weaving efficiency was a reasonable 92%, there was a considerable amount of fiber shedding as well as an increase in the warp breaks in the towel selvage (border area), both of which caused the trial to fail.
EXAMPLE 5
The procedure of Comparative Example C was repeated except that the amount of size on the towel pile yarns was increased to 2.9%. The resulting weaving shows an efficiency greater than 95% and little to no fiber shedding was observed and warp breaks in the selvage were normal or below. | This invention is to a process for sizing spun cotton yarns, especially dyed spun cotton yarns. The process entails treating a cotton-containing yarn with a solution polyacrylamide polymer. The use of this polymer system with a spun cotton yarn has been discovered both to overcome the previous excessive brittleness which had precluded use of polyacrylamide polymers as a size and to produce a fabric which can be overdyed without prior removal of the size. | 3 |
CROSS-REFERENCE TO RELATED APPLICATIONS
This application claims priority to Provisional Patent Application Ser. No. 60/839,024 filed on Aug. 21, 2006 entitled “WATER REMOVAL FROM GAS FLOW CHANNELS OF FUEL CELLS”, the entire contents of which is hereby incorporated by reference.
BACKGROUND
The present invention relates to fuel cells, and more specifically to water management within a fuel cell.
During fuel cell operation, water droplets frequently form on the surface of gas diffusion layers within the fuel cell. Generally, the water droplets migrate through the gas diffusion layers into gas flow channels. In the gas flow channels, movement of the water can be inhibited by pinning of the three-phase region, commonly referred to as the contact line region. In the contact line region, the gas, liquid and solid phases collide.
A balance between keeping the membrane from becoming too dry or too wet must be maintained for efficient and reliable fuel cell operation. At high current densities, the production of liquid water may exceed the capacity of the gas streams to evaporate the water out of the fuel cell stack and drops of water will appear within the gas flow channels. If the water accumulation becomes too great, then the gas flow channel may become completely blocked by water and the fuel cell will “flood.” Therefore, the water drops must be removed from the gas flow channels for reliable operation. Efficient removal of the product water is an important step in fuel cell operation and enables increased commercial utilization of fuel cells.
SUMMARY
In one embodiment, the invention provides an apparatus for water management in a fuel cell. The apparatus includes a fuel cell having a first porous electrode layer, a second porous electrode layer, a proton-conducting membrane positioned between the first electrode and second electrode layers, and a first and second bi-polar distribution plate, wherein the first bi-polar distribution plate is positioned on a top of the first electrode layer and defining a first gas flow channel, and wherein the second bi-polar distribution plate is positioned on a bottom of the second electrode layer and defining a second gas flow channel. The apparatus further includes a mechanism for oscillating liquid water formed in the gas flow channel and configured to remove the liquid water.
In another embodiment, the invention provides a system for operating a fuel cell. The system includes a fuel cell having a first porous electrode layer, a second porous electrode layer, a proton-conducting membrane positioned between the first electrode and second electrode layers, and a first and second bi-polar distribution plate, wherein the first bi-polar distribution plate is positioned on a top of the first electrode layer and defining a first gas flow channel, and wherein the second bi-polar distribution plate is positioned on a bottom of the second electrode layer and defining a second gas flow channel. The system further includes a mechanism for oscillating liquid water formed in the gas flow channel.
In another embodiment, the invention provides in a fuel cell system including a fuel cell, a method of water management for the fuel cell. The method includes passing a gas flow stream through a gas flow channel in the fuel cell, oscillating a liquid water drop in the gas flow channel to the natural frequency of the liquid water drop with a mechanism configured to oscillate a liquid water drop, and removing the liquid water drop from the gas flow channel.
In another embodiment, the invention provides a fluidic oscillator for use with a fuel cell. The fuel cell has a first porous electrode layer, a second porous electrode layer, a proton-conducting membrane positioned between the first electrode and the second electrode layers, and a first and second bi-polar distribution plate, wherein the first bi-polar distribution plate is positioned on a top of the first electrode layer and defining a first gas flow channel, and wherein the second bi-polar distribution plate is positioned on a bottom of the second electrode layer and defining a second gas flow channel. The fluidic oscillator includes an inlet port for receiving a fluid flow, a first outlet port communicating between the inlet port and the first gas flow channel, a second outlet port communicating between the inlet port and the second gas flow channel, a first control port configured to transmit a signal from the first outlet port to the inlet port, and a second control port configured to transmit a signal from the second outlet port to the inlet port. The fluid flow has a flow characteristic wherein when the flow characteristic drops below a threshold parameter, the fluidic oscillator produces a cyclic force to oscillate the water droplet.
Other aspects of the invention will become apparent by consideration of the detailed description and accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a fuel cell according to one embodiment of the present invention.
FIG. 2 is the fuel cell of FIG. 1 and a mechanism embodying the present invention.
FIG. 3 is a schematic of an oscillating liquid water drop.
FIG. 4 is a schematic of a fluidic oscillator for use with the fuel cell of FIG. 1 according to one embodiment of the present invention.
DETAILED DESCRIPTION
Before any embodiments of the invention are explained in detail, it is to be understood that the invention is not limited in its application to the details of construction and the arrangement of components set forth in the following description or illustrated in the following drawings. The invention is capable of other embodiments and of being practiced or of being carried out in various ways. Also, it is to be understood that the phraseology and terminology used herein is 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 specified or limited otherwise, the terms “mounted,” “connected,” “supported,” and “coupled” and variations thereof are used broadly and encompass both direct and indirect mountings, connections, supports, and couplings. Further, “connected” and “coupled” are not restricted to physical or mechanical connections or couplings.
In addition, and as described in subsequent paragraphs, the specific mechanical configuration illustrated in the drawings are intended to exemplify embodiments of the invention and that other alternative mechanical configurations are possible.
FIG. 1 illustrates a fuel cell 10 according to one embodiment of the present invention. In general, polymer electrolyte membrane (PEM) fuel cells 10 have a membrane electrode assembly 14 consisting of an ion-exchange, or electrolyte, membrane 18 disposed between two electrode layers, typically comprised of porous, electrically conductive sheet material. In some embodiments, the electrode layers are disposed between two gas diffusion layers, a cathode layer 22 and an anode layer 26 . In some embodiments, the gas diffusion layers may include a generally rough, nonwetting, chemically inhomogenous surface, such as provided by teflonated carbon paper with or without a microporous layer. In a fuel cell 10 , and as illustrated in FIG. 1 , the membrane electrode assembly 14 is interposed between two separator plates 30 . The separator plates 30 are substantially impermeable to reactant fluid streams. The separator plates 30 generally define gas flow channels 34 and are bi-polar distribution plates. The gas flow channels 34 are formed within the separator plates 30 during the manufacturing process, such that the gas flow channels 34 can be stamped, machined, or the like into the separator plates 30 .
Typically, a PEM fuel cell 10 operates via a controlled hydrogen-oxygen reaction, wherein the byproducts of the reaction are heat and water. Accordingly, water product 38 forms within the membrane electrode assembly 14 and further migrates through the layers 22 , 26 . The water 38 further migrates to the gas flow channels 34 . Water droplets 38 move through the gas flow channels 34 and out of the fuel cell 10 via a gas flow. However, at times, the movement of the water droplets 38 in the gas flow channel 34 can be inhibited by pinning of the three-phase region. The three-phase region is the line of contact where the gas, liquid, and solid phases collide. At high gas flow rates, the water droplets 38 can be removed via gas flow. However, at low gas flow rates, the water droplets 38 can remain pinned to the gas diffusion layer 22 , 26 and continue to grow. As the water droplets 38 grow, the gas flow channels 34 can become clogged with the water droplets 38 .
When the gas flow channels 34 become clogged with water droplets 34 , it becomes necessary to dislodge the water droplets 38 for efficient fuel cell operation. The water droplets 38 can be removed with a mechanism 42 ( FIG. 2 ) configured to oscillate the water droplets 38 at or near the water droplets' natural frequency. For oscillation near the natural frequency of the liquid-gas surface of the water droplet, minimal energy is required to induce large surface oscillations and relatively large inertia within the water droplet. As shown in FIG. 3 , the oscillating force 46 acts on the liquid-gas surface of the water droplet 38 . The oscillating force 46 is a cyclic force acting on the water droplet 38 . The oscillation of the water droplet 38 utilizes the inertia of the water droplet to overcome the pinning energy of the drop contact line through oscillation at the drop surface, oscillation of the drop surface near the natural frequency, or oscillation of the drop surface at the natural frequency. The oscillating frequency can be kept constant (in which case the water droplets are permitted to grow until they reach a size at which the oscillating frequency matches the natural frequency of the water droplet), or can be varied to meet the natural frequency of various sizes of water droplets.
The mechanism 42 for oscillating the water droplet 38 at or near its natural frequency to remove the water droplet 38 produces a cyclic force, that can include, but is not limited to a pulsed gas flow via a fluidic oscillator positioned substantially entirely in an inlet manifold 54 ( FIG. 2 ) of the fuel cell 10 , a cyclic acoustic wave, a pulsed electromagnetic wave, and mechanical vibrations.
FIG. 4 shows a schematic illustration of one embodiment of a fluidic oscillator 50 according to the present invention. The fluidic oscillator 50 includes an inlet port 58 , first and second feedback conduits 62 a , 62 b , and first and second outlet ports 66 a , 66 b . The first and second feedback conduits 62 a , 62 b each have a control port 70 a , 70 b , and a start port 74 a , 74 b , respectively. The inlet port 58 is configured to receive a flow of fluid. The fluid flow is comprised of fuel cell components, such as hydrogen and water. The inlet port 58 includes a nozzle 78 that accelerates the fluid flow into a bridge 82 . The bridge 82 provides fluid communication between the inlet port 58 and the first and second outlet ports 66 a , 66 b . The fluid flow from the nozzle 78 is a focused jet stream, resulting in a reduced static pressure. Each start port 74 a , 74 b communicates with the respective outlet ports 66 a , 66 b . Each control port 70 a , 70 b communicates with the output end of the nozzle 78 , where the nozzle 78 meets the bridge 82 . The outlet ports 66 a , 66 b can further communicate with gas flow channels 34 .
When operation of the fuel cell is initiated, the focused jet stream flowing out of nozzle 78 into bridge 82 flows into both outlet ports 66 a , 66 b . The flow eventually favors one side or other (first outlet port 66 a in this example), and fluid flow is directed from the inlet port 58 to the first outlet port 66 a . Fluid flow to the first outlet port 66 a initiates a pressure pulse at the first start port 74 a that travels through the first feedback conduit 62 a to the first control port 70 a . The pressure pulse exits the first feedback conduit 62 a at the first control port 70 a and deflects the fluid flow to the second outlet port 66 b . Fluid flow to the second outlet port 66 b initiates a pressure pulse at the second start port 74 b that travels through the second feedback conduit 62 b to the second control port 70 b . The pressure pulse exits the second feedback conduit 62 b at the second control port 70 b and deflects the fluid flow to the first outlet port 66 a . The fluidic oscillator 50 operates in this manner to create the fluid flow oscillations. Additionally, the focused jet of fluid flow from the nozzle 78 results in a low static pressure, which allows for a more easily deflected fluid flow when acted upon by the pressure pulses from the control ports 70 a , 70 b than if the fluid flow had a higher static pressure. The feedback conduits 62 a , 62 b provide closed loop feedback to deliver the pressure pulses to the control ports 70 a , 70 b , so that the oscillator 50 is not vented. In a fuel cell application, it is desirable to avoid venting because the fluid flow contains hydrogen.
The pressure pulse in the feedback conduits 62 a , 62 b is an acoustic wave, or operates at the speed of sound. The frequency of the oscillations can depend on any flow parameters that will affect the speed of sound, including, but not limited to, density, pressure, temperature, and relative humidity. The frequency of the oscillation can also be affected by factors, including, but not limited to the length of the feedback conduits, or another factor that will affect the time of travel of an acoustical wave from the start ends 74 a , 74 b to the control ports 70 a , 70 b for a given wave speed.
The pulsed fluid flow causes water droplet motion. During the onset of motion within the water droplet, the inertia of the water droplet is significant; whereas, at steady flow, the inertia becomes insignificant. The timing and amplitude of the pulses, or the cyclic force, produces a more steady motion of the water droplets than steady shear flow by utilizing the transient liquid momentum to overcome the dissipation due to contact line motion.
Various features and advantages of the invention are set forth in the following claims. | An apparatus for water management in a fuel cell. The apparatus includes a fuel cell having a first porous electrode layer, a second porous electrode layer, a proton-conducting membrane positioned between the first electrode and second electrode layers, and a first and second bi-polar distribution plate, wherein the first bi-polar distribution plate is positioned on a top of the first electrode layer and defining a first gas flow channel, and wherein the second bi-polar distribution plate is positioned on a bottom of the second electrode layer and defining a second gas flow channel. The apparatus further includes a mechanism for oscillating liquid water formed in the gas flow channel and configured to remove the liquid water. | 7 |
RELATED APPLICATION
[0001] This application is a continuation-in-part of, and hereby claims priority under 35 U.S.C. § 120 to, U.S. patent application Ser. No. 10/663,609, entitled, “Method and Apparatus for Manipulating Two-Dimensional Windows Within a Three-Dimensional Display Model,” by inventor Hideya Kawahara, filed 15 Sep. 2003 (Attorney Docket No. SUN04-0195-EKL).
BACKGROUND
[0002] 1. Field of the Invention
[0003] The present invention relates to user interfaces for computer systems. More specifically, the present invention relates to a method and an apparatus for displaying related two-dimensional windows within a three-dimensional display model.
[0004] 2. Related Art
[0005] Today, most personal computers and other high-end devices support window-based graphical user interfaces (GUIs), which were originally developed back in the 1980's. These window-based interfaces allow a user to manipulate windows through a pointing device (such as a mouse), in much the same way that pages can be manipulated on a desktop. However, because of limitations on graphical processing power at the time windows were being developed, many of the design decisions for windows were made with computational efficiency in mind. In particular, window-based systems provide a very flat (two-dimensional) 2D user experience, and windows are typically manipulated using operations that keep modifications of display pixels to a minimum. Even today's desktop environments like Microsoft Windows (distributed by the Microsoft Corporation of Redmond, Wash.) include vestiges of design decisions made back then.
[0006] In recent years, because of increasing computational requirements of 3D applications, especially 3D games, the graphical processing power of personal computers and other high-end devices has increased dramatically. For example, a middle range PC graphics card, the “GeForce2 GTS” distributed by the NVIDIA Corporation of Sunnyvale, Calif., provides a 3D rendering speed of 25 million polygon-per-second, and Microsoft's “Xbox” game console provides 125 million polygon-per-second. These numbers are significantly better than those of high-end graphics workstation in the early 1990's, which cost tens of thousands (and even hundreds of thousands) of dollars.
[0007] As graphical processing power has increased in recent years, a number of 3D user interfaces have been developed. These 3D interfaces typically allow a user to navigate through and manipulate 3D objects. However, these 3D interfaces are mainly focused on exploiting 3D capabilities, while little attention has been given to supporting existing, legacy window-based 2D applications within these 3D user interfaces.
[0008] If a 3D interface is to be commercially viable, it is crucial to be able to support the large existing base of legacy 2D applications. One of the problems that arises in trying to use 2D applications within a 3D interface is how to arrange related 2D windows in an intuitive and convenient way within the 3D interface. Note that within a 3D interface, it is possible to indicate relationships between 2D windows through a large number of possible spatial relationships.
[0009] Hence, what needed is a method and an apparatus for displaying related 2D window-based applications within a 3D user interface.
SUMMARY
[0010] One embodiment of the present invention provides a system that facilitates displaying multiple two-dimensional (2D) windows with related content within a three-dimensional (3D) display model. The system starts by receiving a command to display a first window within the 3D display model. In response to the command, the system displays the content of the first window on a first surface of a 3D object. Next, the system receives a command to display a second window within the 3D display model, wherein content of the second window is related to content of the first window. The system then displays content of the second window on a second surface of the 3D object.
[0011] In a variation on this embodiment, the second surface of the 3D object is located on the opposite side of the 3D object from the first surface, wherein only one of the first surface of the 3D object and the second surface of the 3D object is visible at any given time.
[0012] In a further variation, the system rotates the 3D object so that the second surface is visible.
[0013] In a variation on this embodiment, the system receives a command to display a third window within the 3D display model. In response to this command, the system displays content of the third window on a surface of a second 3D object, wherein the second 3D object is located in close proximity to the 3D object in the 3D display model.
[0014] In a further variation, the system receives a modal dialog related to the content of the first window, wherein the modal dialog must be responded to before any other action may be taken on an application. In order to display the modal dialog, the system rotates the 3D object so that the second surface is visible and the first surface is hidden, and displays the modal dialog on the second surface.
[0015] In a further variation, when the modal dialog is displayed, the system rotates any related 3D objects so that related content on the surface of the related 3D objects is not visible until the modal dialog is acknowledged.
[0016] In a variation on this embodiment, the first window and the second window are associated with different applications.
[0017] In a variation on this embodiment, upon receiving the command to display the second window, the system looks up an identifier for the second window in a lookup table that contains entries specifying relationships between windows. The system then determines if the second window is related to the first window, and if so, displays content of the second window on the second surface of the 3D object. If the first and second windows are unrelated, the system displays content of the second window on a surface of a distant 3D object, which is not located in close proximity to the 3D object in the 3D display model.
[0018] In a variation on this embodiment, the system receives a notification that the first window and the second window contain related content. In response to this notification, the system creates an association between the first window and the second window in a lookup table.
[0019] In a variation on this embodiment, the 3D object is stacked on top of the second 3D object so that the second 3D object is obscured by the 3D object from the viewpoint of a user.
[0020] In a variation on this embodiment, the 3D object is translucent so that the second 3D object is visible through the 3D object.
BRIEF DESCRIPTION OF THE FIGURES
[0021] FIG. 1 illustrates a 3D display model with supporting components in accordance with an embodiment of the present invention.
[0022] FIG. 2 presents a flow chart illustrating how input from a pointing device is communicated to an application associated with a window in a 3D display model in accordance with an embodiment of the present invention.
[0023] FIG. 3 presents a flow chart illustrating how input from a pointing device causes objects to rotate around a viewpoint in the 3D display model in accordance with an embodiment of the present invention.
[0024] FIG. 4A illustrates an exemplary window in the 3D display model in accordance with an embodiment of the present invention.
[0025] FIG. 4B illustrates how the exemplary window is rotated to display application information on the backside of the window in accordance with an embodiment of the present invention.
[0026] FIG. 4C presents a flow chart of the process of rotating a window in accordance with an embodiment of the present invention.
[0027] FIG. 5 illustrates a 3D object with multiple viewing surfaces in accordance with an embodiment of the present invention.
[0028] FIG. 6 presents a flow chart of the process of displaying a window in accordance with an embodiment of the present invention.
[0029] FIG. 7 presents a flow chart of the process of displaying a modal dialog in accordance with an embodiment of the present invention.
[0030] FIG. 8 illustrates object translucency in accordance with an embodiment of the present invention.
[0031] Table 1 illustrates an exemplary lookup table in accordance with an embodiment of the present invention.
DETAILED DESCRIPTION
[0032] The following description is presented to enable any person skilled in the art to make and use the invention, and is provided in the context of a particular application and its requirements. Various modifications to the disclosed embodiments will be readily apparent to those skilled in the art, and the general principles defined herein may be applied to other embodiments and applications without departing from the spirit and scope of the present invention. Thus, the present invention is not intended to be limited to the embodiments shown, but is to be accorded the widest scope consistent with the principles and features disclosed herein.
[0033] The data structures and code described in this detailed description are typically stored on a-computer readable storage medium, which may be any device or medium that can store code and/or data for use by a computer system. This includes, but is not limited to, magnetic and optical storage devices such as disk drives, magnetic tape, CDs (compact discs) and DVDs (digital versatile discs or digital video discs), and computer instruction signals embodied in a transmission medium (with or without a carrier wave upon which the signals are modulated). For example, the transmission medium may include a communications network, such as the Internet.
[heading-0034] 3D Display Model
[0035] FIG. 1 illustrates 3D display model 102 with supporting components in accordance with an embodiment of the present invention. More specifically, the top portion of FIG. 1 illustrates 3D display model 102 , which includes a number of 3D objects including window 108 , window 110 , and 3D object 111 . Note that windows 108 and 110 are actually 3D objects which represent 2D windows. Hence, windows 108 and 110 can be moved and rotated within 3D display model 102 , while they provide a 2D output and receive input for associated 2D applications. 3D display model 102 can additionally include a background (which is not shown).
[0036] Windows 108 and 110 can be associated with a number of window attributes. For example, window 110 can include x, y, and z position attributes that specify the 3D position of the center of window 110 within 3D display model 102 , as well as a rotation attributes that specify rotations of window I 1 O around horizontal and vertical axes. Window 110 can also be associated with scaling factor, translucency and shape attributes.
[0037] 3D objects within 3D display model 102 are viewed from a viewpoint 106 through a 2D display 104 , which is represented by a 2D rectangle within 3D display model 102 . During the rendering process, various well-known techniques, such as ray tracing, are used to map objects from 3D display model 102 into corresponding locations in 2D display 104 .
[0038] The bottom portion of FIG. 1 illustrates some of the system components that make it possible to map 2D windows into 3D display model 102 in accordance with an embodiment of the present invention. Referring to FIG. 1 , applications 114 and 116 are associated with windows 108 and 110 , respectively. A number of components are involved in facilitating this association. In particular, applications 114 and 116 are associated with xclients 118 and 120 , respectively. Xclients 118 and 120 in turn interact with xserver 122 , which includes an associated xwindow manager. These components work together to render output bitmaps 124 and 126 for applications 114 and 116 to be displayed in windows 108 and 110 , respectively. These bitmaps 124 and 126 are maintained within back buffer 128 .
[0039] Code module 130 causes bitmaps 124 and 126 to be displayed on corresponding windows 108 and 110 . More specifically, code module 130 retrieves bitmap 126 and coverts it into a texture 132 , which is displayed on the front face of window 110 . This is accomplished though interactions with 3D scene manager 134 . Bitmap 124 is similarly mapped into window 108 .
[0040] 3D scene manager 134 can also received input from a 2D pointing device, such as mouse 136 , and can communicate this input to applications 114 and 116 in the following way. 3D scene manger 134 first receives an input specifying a 2D offset from mouse 136 (step 202 ). Next, the system uses this 2D offset to move a cursor 109 to a new position (x 1 , y 1 ) in 2D display 104 (step 204 ).
[0041] The system then determines if cursor 109 overlaps a window in 3D display model 102 (step 206 ). This can be accomplished by projecting a ray 107 from viewpoint 106 through cursor 109 and then determining if the ray intersects a window. If there is no overlap, the process is complete.
[0042] Otherwise, if there is overlap, the system uses the 3D position (x 2 , y 2 , z 2 ) within display model 102 where ray 107 intersects window 110 , as well as attributes of window 110 , such as position and rotation attributes, to determine the 2D position (x 3 , y 3 ) of this intersection with respect to a 2D coordinate system of window 110 (step 208 ). The system then communicates this 2D position (x 3 , y 3 ) to application 116 , which is associated with window 110 (step 210 ).
[0043] 3D scene manger 134 is also coupled to lookup table 135 . Lookup table 135 contains entries specifying relationships between windows. As described later in FIG. 6 , lookup table 135 allows 3D scene manager 134 to determine if windows 108 and 10 should be displayed on separate objects, or if they should be displayed on different sides of the same object within 3D display model 102 .
[0044] Various user inputs, for example through mouse 136 or a keyboard, can be used to manipulate windows within 3D display model 102 .
[heading-0045] Rotation Around Viewpoint
[0046] FIG. 3 presents a flow chart illustrating how input from a pointing device causes objects to rotate around a viewpoint 106 in 3D display model 102 in accordance with an embodiment of the present invention. First, the system receives an input from a 2D pointing device indicating that a rotation is desired (step 302 ). For example, the system can receive a movement input from mouse 136 . In response to this input, the system can rotate objects within the 3D display model around viewpoint 106 , or alternatively around another point within 3D display model 102 (step 304 ). This rotational motion makes it easier for a user to identify window boundaries and also gives the user a feeling of depth and space.
[heading-0047] Displaying Additional Information on Back of Window
[0048] FIG. 4A illustrates an exemplary window 401 in 3D display model 102 , and FIG. 4B illustrates how window 401 is rotated to display additional information on the backside of window 401 in accordance with an embodiment of the present invention. Referring to the flow chart in FIG. 4C , the system first receives a command (possibly through a mouse or a keyboard) to rotate window 401 (step 404 ). In response to this command, the system rotates window 401 so that additional information 402 on the backside of window 401 becomes visible (step 406 ). Additional information 402 can include application information, such as application version information, application settings, application parameters, application properties, and notes associated with a file or a web page that is displayed in the window. In one embodiment of the present invention, the system allows the user to modify application information 402 on the backside of window 401 . This enables the user to change application parameters, if necessary.
[0049] This additional information 402 can also include a window associated with the same application, a window associated with a related application, a window associated with a different application, a modal dialog associated with the application, or a modal dialog associated with the OS.
[heading-0050] 3D Object with Multiple Viewing Surfaces
[0051] FIG. 5 illustrates 3D object 111 with multiple viewing surfaces in accordance with an embodiment of the present invention. In the orientation shown in FIG. 5 , 3D object 111 has 3 visible surfaces, which display window 502 , window 504 , and window 506 . Note that 3D object 111 has additional surfaces that are not visible in the current orientation. Also note that in general, 3D object 111 is not limited to being a slate or a cube, and can be any size or shape, and can have any number of visible surfaces.
[heading-0052] Displaying a Window
[0053] FIG. 6 presents a flow chart of the process of displaying a window in accordance with an embodiment of the present invention. The process starts when 3D scene manager 134 receives a direction to open a new window in 3D display model 102 (step 602 ). 3D scene manager 134 looks-up the title of the window to open in lookup table 135 (step 604 ) and determines if the window title is linked to the title of any of the windows that are currently open within 3D display model 102 (step 606 ). If the title is not linked, or is not listed in lookup table 105 , 3D scene manager 134 opens the window on a new 3D object within 3D display model 102 (step 608 ). However, if the title is linked, 3D scene manager 134 opens the window on a different surface of the 3D object that is displaying the related window (step 610 ). Note that displaying the new window on an existing 3D object might result in changing the orientation of the 3D object so that the pre-existing related window is no-longer visible from viewpoint 106 .
[0054] Table 1 illustrates an exemplary lookup table 135 in accordance with an embodiment of the present invention.
TABLE 1 Front window name Windows that can be placed on the back {circumflex over ( )}Web Browser .*$ {circumflex over ( )}Preferences$|{circumflex over ( )}Alert$ {circumflex over ( )}Editor .*$ {circumflex over ( )}Preferences$|{circumflex over ( )}Save As$|{circumflex over ( )}Open$ {circumflex over ( )}Music Player .*$ {circumflex over ( )}Note Pad$ {circumflex over ( )}Photo Viewer .*$ {circumflex over ( )}Email$
When a request to show a new window is sent to 3D scene manager 134 , 3D scene manager 134 first finds the row in lookup table 135 whose “Front window name” matches the currently focused window based on specific regular expression. Next, 3D scene manager 134 checks if the requested window's title matches to the regular expression shown in the “Windows that can be placed on the back” column. If it matches, 3D scene manager 134 rotates the window by 180 degrees so that the user can see the back side of the window. Finally, 3D scene manager 134 places the requested window on the back side of the window.
Displaying a Modal Dialog
[0057] FIG. 7 presents a flow chart of the process of displaying a modal dialog in accordance with an embodiment of the present invention. The system starts when 3D scene manager 134 is directed to display a modal dialog (step 702 ) or any other dialog that requires user intervention before operations may continue on an open application. 3D scene manager 134 then determines all of the currently visible windows that are affected by the modal dialog (step 704 ). Next, 3D scene manager 134 makes affected windows less visible. This can be accomplished by rotating all of the affected windows so that they are no longer visible to viewpoint 106 (step 706 ). Finally, 3D scene manager 134 displays the modal dialog on the backside of one of the rotated windows (step 708 ).
[heading-0058] Object Translucency
[0059] FIG. 8 illustrates an example where object translucency can be used to facilitate displaying related information in accordance with an embodiment of the present invention. In this example, the 3D interface displays user calendar 802 , group calendar 804 , and stacked objects 806 . Note that stacked objects 806 comprises user calendar 802 placed on top of group calendar 804 as seen from viewpoint 106 . When the cursor is moved off of an object in 3D display model 102 , the object becomes semi-translucent. This allows an observer to see any object located behind or underneath of the object.
[0060] In the illustrated example, when the user locates the mouse cursor over the top of stacked objects 806 , the user will see only user calendar 802 . However, when the cursor is moved off of stacked objects 806 , objects in stacked objects 806 become translucent, thereby allowing the user to see all of the objects simultaneously. In this instance, appointments (designated by the cross-hatched regions) on both user calendar 802 and group calendar 804 are visible to the user at the same time, and allow for the user to visually detect any calendaring conflicts.
[0061] The foregoing descriptions of embodiments of the present invention have been presented for purposes of illustration and description only. They are not intended to be exhaustive or to limit the present invention to the forms disclosed. Accordingly, many modifications and variations will be apparent to practitioners skilled in the art. Additionally, the above disclosure is not intended to limit the present invention. The scope of the present invention is defined by the appended claims. | One embodiment of the present invention provides a system that facilitates displaying multiple two-dimensional (2D) windows with related content within a three-dimensional (3D) display model. The system starts by receiving a command to display a first window within the 3D display model. In response to the command, the system displays the content of the first window on a first surface of a 3D object. Next, the system receives a command to display a second window within the 3D display model, wherein content of the second window is related to content of the first window. The system then displays content of the second window on a second surface of the 3D object. | 6 |
FIELD OF THE INVENTION
The present invention is related to a fan guard structure, and more particular to an improved fan guard structure which imparts a supercharging function to a fan for efficient heat dissipation.
BACKGROUND OF THE INVENTION
Currently, heat-dissipating fans commonly used in personal computers include an axial-flow fan, a centrifugal fan and a cross-flow fan. Of these, the most popular one is supposed to be an axial-flow fan.
A fan is primarily consisted of a rotor device and a fan guard arranged beside the rotor device for supporting the rotor device. Referring to FIG. 1, the fan guard 10 of a conventional axial-flow fan is constructed by a main frame 101 , a motor holder 102 and a plurality of ribs 103 arranged between the main frame 101 and the motor holder 102 . The rotor device 11 includes a motor (not shown) received in the motor holder 102 , a shaft ring 111 connected to and driven by the motor to revolve, and a plurality of rotor blades 112 fixed on the circumferential surface of the shaft ring 111 and revolving with the shaft ring 111 to work on the surrounding air to generate an airflow. Through the work of the rotor blades on the surrounding air, the blast pressure is changed from a relatively low value on the air inlet side into a relatively high value on the air outlet side. That is, there is a blast pressure enhancement on the air outlet side.
Unfortunately, when the airflow further flows through the fan guard having the structure as shown in FIG. 1 and as described above, turbulent flows will be generated after the airflow encounters the ribs so as to have an adverse effect on the blast pressure enhancement. Consequently, the efficiency of the fan is reduced.
SUMMARY OF THE INVENTION
Therefore, an object of the present invention is to provide an improved fan guard structure which has a function of supercharging a fan in addition to supporting a rotor device.
The present invention is related to a fan guard to be mounted beside a rotor device of a fan for supporting the rotor device. Additionally, the fan guard according to the present invention interacts with an airflow generated by the revolution of the rotor blades to supercharge the fan.
The fan guard essentially includes a main frame, and a set of guard blades radially arranged inside the main frame and fixed onto an inner surface of the main frame by each one end thereof. Generally but not definitely, a count of the guard blades is about 1-2 times of that of the rotor blades. Preferably, the other ends of the guard blades are fixed onto a cylindrical motor holder which is located at the center of the main frame, and is hollow for receiving therein a motor used for driving the rotor blades to revolve. Especially preferred, at least one reinforcing ring connecting all of the guard blades is provided for strengthening the far guard. In general, the guard blades are made of plastic. Nevertheless, the guard blades can also be made of a material other than plastic for a desired purpose. For example, they can be made of a metal which is advantageous for heat dissipation.
To assemble the fan, the main frame of the fan guard is coupled to the frame of the rotor device. Alternatively, the main frame of the fan guard is integrally formed with the frame of the rotor device so that the fan can be assembled by installing the non-integrally formed parts into the common frame. The fan guard can be arranged either upstream or downstream of the rotor device. Preferably, the fan guard includes two sets of frame and guard blades respectively arranged by both sides of the rotor device. By properly designing the shapes and the position arrangement of the guard blades relative to the rotor blades, the upstream guard blades can guide air into the rotor device at an angle to make an air inflow to the rotor device have an additional tangential velocity which increases the work of the rotor blades on air, and on the other hand, the downstream guard blades can transform a tangential velocity of an air outflow from the rotor device into a static pressure, both advantageous for supercharging the fan. For example, all of the guard blades are made to have a shape identical to the shape of the rotor blades. As for the position arrangement of the downstream guard blades relative to the upstream rotor blades, one of the guard blades and one of the rotor blades constitute a near letter C configuration in a cross-sectional view instantaneously. Contrarily, the position arrangement of the upstream guard blades relative to the downstream rotor blades makes one of the guard blades and one of the rotor blades constitute a near letter S configuration in a cross-sectional view instantaneously.
Furthermore, by taking the combination of a fan guard according to the present invention and a rotor device as a fan unit, a fan can be designed to include a plurality of such fan units to enhance efficiency.
BRIEF DESCRIPTION OF THE DRAWING
The present invention may best be understood through the following description with reference to the accompanying drawings, in which:
FIG. 1 is a schematic diagram showing a conventional axial flow fan;
FIG. 2A is a resolving diagram of a first preferred embodiment of a fan according to the present invention;
FIG. 2B is a perspective diagram of the assembled fan of FIG. 2A with the rotor device facing forwards;
FIG. 3 is a cross-sectional view of a rotor blade and a guard blade of the fan of FIG. 2;
FIG. 4 is a cross-sectional view of a rotor blade and a guard blade of a second preferred embodiment of a fan according to the present invention;
FIG. 5A is a resolving diagram of a third preferred embodiment of a fan according to the present invention;
FIG. 5B is a cross-sectional view of a rotor blade and a guard blade of the fan of FIG. 5A;
FIG. 6 is a cross-sectional view of a rotor blade and a guard blade of a fourth preferred embodiment of a fan according to the present invention;
FIG. 7 is a partially resolving diagram of a fifth preferred embodiment of a fan according to the present invention; and
FIG. 8 is a perspective diagram of a sixth preferred embodiment of a fan according to the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
The present invention will now be described more specifically with reference to the following embodiments. It is to be noted that the following descriptions of preferred embodiments of this invention are presented herein for purpose of illustration and description only; it is not intended to be exhaustive or to be limited to the precise form disclosed. On the other hand, all arrows shown in the drawings are used for schematically illustrating the directions of airflows and velocities, and the length of the arrows does not indicate the measure of the corresponding items.
Please refer to FIG. 2A which schematically shows a rotor device and a preferred embodiment of a fan guard according to the present invention. The rotor device 21 , as conventionally used, includes a motor 211 , a shaft ring 212 connected to the motor 211 , and a plurality of rotor blades 213 fixed on the circumferential surface of the shaft ring 212 . The fan guard 20 includes a main frame 201 , a motor holder 202 , and a plurality of guard blades 203 . The motor holder 202 is a hollow cylinder located at the center inside the frame for receiving therein the motor 211 . The guard blades 203 are radially disposed within the main frame 201 . One end 2031 of each of the guard blades 203 is fixed onto the inner surface 2011 of the main frame 201 and the other end 2032 thereof is fixed onto the circumferential surface 2021 of the motor holder 202 . In this embodiment, the frames of the fan guard and the rotor device are integrally formed as the main frame 201 . In other words, the motor 211 , shaft ring 212 , rotor blades 213 , motor holder 202 , and guard blades 203 are all positioned inside the main frame 201 .
The assembled fan is shown on FIG. 2 B. In this embodiment, the rotor blades are located upstream of the guard blades. When the fan operates, the motor 211 (see FIG. 2A) drives the shaft ring 212 with the rotor blades 213 to revolve. The revolution of the rotor blades 213 results in work on the surrounding air to generate an airflow. The arrows Fi and Fo in the figure indicates the air inflow and the air outflow, respectively. Through the work of the rotor blades on the surrounding air, the blast pressure is changed from a relatively low value on the air inlet (Fi) side into a relatively high value on the air outlet (Fm, FIG. 3) side. That is, there is a blast pressure enhancement on the air outlet (Fm) side. According to the present invention, the blast pressure can be further increased on the air outflow (Fo) side through the guard blades of the fan guard for the reason described as follows.
Please refer to FIG. 3 . In order to concretely illustrate the arrangement of the guard blades, an upstream rotor blade 313 which can be any one of the rotor blades and a downstream guard blade 303 which can be any one of the guard blades, are shown in a cross-sectional view, and a specific moment that a leading point A of the guard blade 303 is moved to be axially aligned with the trailing point B of the rotor blade 313 is taken to facilitate to describe the position relationship between the selected rotor blade and guard blade. As shown, the rotor and the guard blades 313 and 303 constitute a near letter C configuration.
When the rotor device operates to have the rotor blade 313 revolve at a tangential velocity Vr, the airflow arriving at the guard blade 303 has an axial velocity and a tangential velocity. Due to conservation of mass, the axial velocity will not change through the entire guard blade 303 , and is represented by a reference symbol Va in FIG. 3 . The tangential velocity, however, varies from a relatively high value Vt approximating the velocity Vr of the rotor blade to a relatively low value Vt' down to zero. According to the Bernoulli's Law, the pressure will increase with the decrease of velocity. The tangential velocity of the airflow Fm will be transformed into a static pressure. Accordingly, the blast pressure further rises through the fan guard, and the fan is thus supercharged.
Although such a near C configuration is exemplified as above to describe a preferred embodiment, other configurations are acceptable as long as the purpose of transforming a tangential velocity into a static pressure can be achieved.
In another embodiment according to the present invention, the guard blades are arranged upstream of the rotor blades. As shown in FIG. 4, the position relationship between an upstream guard blade 403 and a downstream rotor blade 413 is illustrated at a moment that a leading point C of the rotor blade 403 is moved to follow the camber line CL of the guard blade 403 . The guard and rotor blades 403 and 413 at such moment constitute a near letter S configuration.
When the rotor device operates to have the rotor blade 413 revolve at a tangential velocity Vr, the guard blade 403 guide air into the rotor blade 413 at an angle. Consequently, the air outflow from the guard blade 403 has an axial velocity Va and a tangential velocity Vt, and thus the airflow arriving at the rotor blade 413 has a tangential velocity of Vr+Vt. As known, the increase of the tangential velocity enhances the work of the rotor blades on air, so in this way, the fan is supercharged.
Although such a near S configuration is exemplified as above to describe a preferred embodiment, other configurations are acceptable as long as the purpose of providing an additional tangential velocity can be achieved.
Please now refer to FIGS. 5-8 which schematically show several composite fans which include a plurality of fan guards according to the present invention and/or rotor devices to further enhance fan efficiency.
The composite fan shown in FIGS. 5A and 5B is assembled by screwing the frames 511 , 521 of the rotor devices 51 , 52 and the frame 501 of the fan guard 50 together (FIG. 5A) so that the guard blades 503 can be upstream of the rotor blades 523 and downstream of the rotor blades 513 (FIG. 5B) to simultaneously enhance the efficiencies of the upstream rotor device 51 and downstream rotor device 523 so as to supercharge the composite fan.
FIG. 6 schematically shows another embodiment of composite fan according to the present invention. In this embodiment, there are a set of guard blades 603 located upstream of rotor blades 613 and another set of guard blades 623 located downstream of the rotor blades 613 to both enhance the efficiency of the rotor device. By this way, the composite fan is supercharged.
A further embodiment of a composite fan is shown on FIG. 7 wherein two fan units, each consisting of a fan guard 70 according to the present invention and a rotor device 71 , are directly coupled to form the composite fan.
On the basis of the above fan guard skeletons, at least one reinforcing ring connecting the guard blades are preferably arranged for strengthening the fan guard. Referring to FIG. 8, the fan guard 80 includes two reinforcing rings 814 .
Although the guard blades in the above embodiments are exemplified to have a shape identical to the shape of the rotor blades, they can be plane plates or any other suitable shapes as long as the efficiency of the fan can be enhanced thereby.
The number of the guard blades need not be particularly limited, but one to two times of the count of the rotor blades will result in satisfactory performance.
The guard blades can be made of plastic. Nevertheless, the guard blades can also be made of a material other than plastic for a desired purpose. For example, when they are made of metal, the guard blades can serve as efficient heat-dissipating plates to further enhance the heat-dissipating efficiency.
To sum up, according to the present invention, the performance of a fan can be easily improved by changing the structure of the fan guard conventionally only used for supporting the fan. On the other hand, it is even advantageous because for the application to compact products, the high performance of the fan according to the present invention allows the fan size to be reduced so as to be installed properly.
While the invention has been described in terms of what are presently considered to be the most practical and preferred embodiments, it is to be understood that the invention need not be limited to the disclosed embodiment. On the contrary, it is intended to cover various modifications and similar arrangements included within the spirit and scope of the appended claims which are to be accorded with the broadest interpretation so as to encompass all such modifications and similar structures. | A fan guard has a function of supercharging a fan in addition to supporting a rotor device is disclosed. The fan guard is to be mounted beside the rotor device for supporting the rotor device, and additionally, the fan guard interacts with an airflow generated by the revolution of the rotor blades to supercharge the fan. The fan guard essentially includes a main frame, and a set of guard blades radially arranged inside the main frame and fixed onto an inner surface of the main frame by each one end thereof. Each of the guard blades is preferred to have a shape similar to the shape of the rotor blades, and the set of guard blades can be arranged either upstream or downstream of the rotor blades. | 5 |
CROSS REFERENCE TO RELATED APPLICATION
This application claims the priority of German Application No. 196 51 894.6 filed Dec. 13, 1996, which is incorporated herein by reference.
BACKGROUND OF THE INVENTION
This invention relates to a carding machine for processing textile fibers such as cotton, chemical fibers or the like and includes travelling flats composed of flat bars provided with a clothing. Between the points of the flat bar clothings and the points of the carding cylinder clothing a clearance is maintained through which the fiber material passes as it is being treated by the clothings. Opposite ends of the flat bars glide on convex slide guides each formed of a flexible element positioned on a convex surface of the associated flexible bend.
In a known arrangement the distance between the convex outer surface of the slide guide on the one hand and the concave inner surface of the slide guide and the convex outer surface of the flexible bend on the other hand, is constant along the circumferential direction of the carding cylinder. The convex outer surface and the concave inner surface of the slide guide and the convex outer surface of the flexible bend are arranged concentrically to the rotary axis of the main carding cylinder. The flexible bend has a recess, for example, a groove in which the slide guide is stationarily supported. In order to vary the distance between the points of the flat bar clothings and the points of the cylinder clothing for the purpose of altering the carding intensity, because, for example, the nep number has increased and/or a fiber shortening in the fiber web has occurred, the position of the flexible bend is altered by adjusting a plurality of setscrews, to thus change the position of the slide guide. This operation results in a raising or lowering of the flat bars, thus changing the distance between the points of the flat bar clothings, on the one hand, and the points of the carding cylinder clothing, on the other hand. Such an adjusting process of the flexible bend is, however, circumstantial. It is a further disadvantage of the conventional arrangement that the geometry of the flexible bend depends from the number of the setscrews. Further, for effecting the change, the carding machine has to be at a standstill and lateral carding elements such as drive, suction arrangement and flat bars have to be removed and subsequently reassembled. Such an operation involves a significant outlay of the assembling operation. It is also a drawback that because of the necessary standstill, the production of the carding machine is interrupted.
SUMMARY OF THE INVENTION
It is an object of the invention to provide an improved device of the above-outlined type from which the discussed disadvantages are eliminated and which permits, while the carding machine is operating, an adjustment of the distance between the clothing points of the flat bars and the clothing points of the carding cylinder in a simple manner, particularly for the purpose of altering the carding intensity.
This object and others to become apparent as the specification progresses, are accomplished by the invention, according to which, briefly stated, the carding machine includes a main carding cylinder having a cylinder axis and a cylinder clothing; and traveling flats cooperating with the main carding cylinder along a circumferential length portion thereof. The traveling flats include a plurality of flat bars each having a flat bar clothing cooperating with the cylinder clothing; and a drive for moving the flat bars in unison in an endless path having a working leg in which the flat bar clothings cooperate with the cylinder clothing and a return leg. The working leg extends circumferentially about a portion of the main carding cylinder. The carding machine further has a flexible bend having a convex surface and being supported on the machine frame laterally of the main carding cylinder; and a slide guide supported on the flexible bend. The slide guide has a convex surface supporting the flat bars for sliding motion thereon along the working leg. The radial position of the convex surface of the slide guide relative to the cylinder axis determines the radial clothing point distance between the clothing points of the flat bar clothings and the clothing points of the cylinder clothing. Further, an adjusting device is provided for radially displacing the slide guide such that the radial clothing point distance remains uniform at all locations along the working leg.
By virtue of the invention the carding intensity may be varied automatically during operation as a function of technological magnitudes such as nep number and/or fiber damage (fiber shortening). It is an additional particular advantage of the invention that after adjustment of the slide guide the distance between the clothing points of the flats and the clothing points of the cylinder remain identical as viewed circumferentially, whereby a significant improvement of the produced sliver is achieved. Advantageously, the slide guide is flexible to ensure that the arcuate shape of the outer surface of the slide guide is adaptable so that in this manner the uniformity of the distance between the flats clothing and the cylinder clothing is securely maintained at all locations over the circumference. It is a further advantage of the invention that the adjustment may be effected continuously during operation, either automatically or by actuating a push-button, thus eliminating the need for any time-consuming assembling operation or down time. It is a further particular advantage of the invention that the convex outer surface of the slide guide--on which the flat bar heads are supported--is, on either side of the carding machine, shifted in a radial direction concentrically to the axis of the carding cylinder by camming action of elements which are displaced relative to one another in the circumferential direction, parallel to the cylinder surface. In this manner the radial position of the flat bar-supporting slide guide may be changed by infinitely small increments.
The invention has the following additional advantageous features:
The distance between the convex outer surface and the concave inner surface of the slide guide changes as viewed in a circumferential direction and, at the same time, the distance between the convex supporting surface of the flexible bend (on which the slide guide is positioned) and the cylinder axis changes with an opposite sign as viewed in the same circumferential direction so that the sum of the two distances at all locations along the circumference is constant. A relative displacement between the slide guide and the flexible bend in the circumferential direction causes, by camming action, a radial shift of the slide guide and thus the radial position of the flat bars and hence the distance between the points of the flat bar clothings and the points of the cylinder clothing is altered.
In another advantageous embodiment where the distance between the convex outer surface and the concave inner surface of the slide guide is circumferentially constant, an intermediate member is provided between the slide guide and the supporting surface of the flexible bend, and the distance between the convex outer surface and the concave inner surface of the intermediate member changes as viewed in a circumferential direction and, at the same time, the distance between the convex supporting surface of the flexible bend (on which the intermediate member is positioned) and the cylinder axis changes with an opposite sign as viewed in the same circumferential direction so that the sum of the two distances at all locations along the circumference is constant. A relative displacement between the intermediate member and the flexible bend in the circumferential direction causes, by camming action, a radial shift of the slide guide and thus the radial position of the flat bars and hence the distance between the points of the flat bar clothings and the points of the cylinder clothing is altered.
In another advantageous embodiment where the distance between the convex outer surface and the concave inner surface of the flexible bend is circumferentially constant, an intermediate member is provided between the slide guide and the supporting surface of the flexible bend, and the distance between the convex outer surface and the concave inner surface of the slide guide changes as viewed in a circumferential direction and, at the same time, the distance between the convex supporting surface of the intermediate member (on which the slide guide is positioned) and the cylinder axis changes with an opposite sign as viewed in the same circumferential direction so that the sum of the two distances at all locations along the circumference is constant. A relative displacement between the intermediate member and the slide guide in the circumferential direction causes, by camming action, a radial shift of the slide guide and thus the radial position of the flat bars and hence the distance between the points of the flat bar clothings and the points of the cylinder clothing is altered.
According to another preferred embodiment of the invention in which the distance between the convex outer surface and the concave inner surface of the slide guide as well as the distance between the convex outer surface and the concave inner surface of the flexible bend are constant, first and second superposed intermediate members are provided between the slide guide and the supporting surface of the flexible bend, and the distance between the convex outer surface and the convex inner surface of the first intermediate member changes in the circumferential direction and the distance between the convex outer surface of the second intermediate member and the axis of the carding cylinder changes with an opposite sign in the same circumferential direction, so that the sum of both distances at all locations is constant along the circumference. A relative displacement between the first and second intermediate members causes, by camming action, a radial shift of the slide guide and thus the radial position of the flat bars and hence the distance between the points of the flat bar clothings and the points of the cylinder clothing is altered.
The intermediate member or members are formed by a flexible element, such as a metal ribbon (for example, a steel ribbon).
The slide guide and/or the intermediate member or members are made of a synthetic material which has a low coefficient of friction and which is reinforced, for example, by glass fibers, carbon fibers or the like.
The slide guide and/or the intermediate member or members are made of a flexible metal band (for example, a steel band).
The intermediate member, the concave inner surface of the slide guide, the concave supporting surface of the flexible bend and/or the bottom surface of the groove are shaped by machining, for example, grinding.
A displacing device, including a motor and setting elements (such as a linkage, a toothed rack, a gear, rotary joints and the like) is provided for circumferentially shifting the slide guide and/or the intermediate member or members and/or the flexible bend.
The displacing device engages essentially the middle of the slide guide and/or the intermediate member or members.
Between the slide guide and/or the intermediate member or members and the driving device a transmission element is provided.
The ends of the slide guide and/or the intermediate member or members are secured to driven winches.
The slide guide and/or the intermediate member or members are endless belts looped around at least two support rollers, at least one of which is driven, for example, by a motor.
Externally of the flexible bend the slide guide and/or the intermediate member or members have teeth meshing with a driven gear.
The slide guide cooperates with a band-like element which essentially has the shape of an arcuately bent wedge; the slide guide and the band-shaped element are circumferentially displaceable.
The driving device, for example, a motor, for displacing the slide guide and/or the intermediate member or members and/or the flexible bend is connected to an electronic control and regulating device, such as a microcomputer.
Measuring members for detecting fiber lengths, the nep number and the distance between the points of the flat clothings and the points of the carding cylinder clothing are connected to the electronic control and regulating device.
A switching element for actuating the driving device is connected to the electronic control and regulating device.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic side elevational view of a carding machine adapted to incorporate the device according to the invention.
FIG. 2 is a fragmentary schematic side elevational view of a carding cylinder, travelling flats and support therefor.
FIG. 3 is a schematic side elevational view of a preferred embodiment of the invention, showing a flexible bend and a shiftable slide guide.
FIG. 4 is a schematic side elevational view of another preferred embodiment of the invention, showing a flexible bend, a slide guide and a shiftable intermediate member.
FIG. 5 is a schematic side elevational view of yet another preferred embodiment of the invention, showing a flexible bend, a shiftable slide guide and a shiftable intermediate member.
FIG. 6 is a schematic side elevational view of a further preferred embodiment of the invention, showing a flexible bend with two shiftable intermediate members.
FIG. 7a is a schematic side elevational view of a flexible bend and a slide guide received in a groove thereof.
FIG. 7b is a sectional view taken along line VIIb--VIIb of FIG. 7a.
FIG. 8a is a schematic side elevational view of a flexible bend as well as an intermediate member and a slide guide nested in a groove of the flexible bend.
FIG. 8b is a sectional view taken along line VIIIb--VIIIb of FIG. 8a.
FIG. 9a is a schematic side elevational view of a flexible bend, a slide guide depicted in a first position and travelling flats supported on the slide guide.
FIG. 9b is an illustration similar to FIG. 9a showing the slide guide in a second position.
FIG. 10 is a side elevational view of a rack-and-pinion drive for circumferentially shifting the slide guide.
FIG. 11 is a schematic side elevational view of a slide guide and winches arranged at opposite ends thereof.
FIG. 12 is a schematic side elevational view of a slide guide formed as an endless circulating band element.
FIG. 13 is a schematic side elevational view of a spring loaded slide guide.
FIG. 14 is a block diagram of an electronic control and regulating device to which there are connected at least one nep sensor, a fiber length sensor and a setting device, such as a motor for changing the position of the slide guide.
FIG. 15 is a schematic sectional front elevational view of a flat bar cooperating with a carding cylinder and supported on a slide guide.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIG. 1 shows a carding machine CM which may be an EXACTACARD DK 803 model manufactured by Trutzschler GmbH & Co. KG, Monchengladbach, Germany. The carding machine CM has a feed roller 1, a feed plate 2 cooperating therewith, lickerins 3a, 3b, 3c, a main carding cylinder 4 having a rotary axis M, a doffer 5, a stripping roll 6 cooperating with the doffer 5, cooperating crushing rolls 7, 8, a web guiding element 9, a sliver trumpet 10, cooperating calender rolls 11, 12, travelling flats 13 including flat bars 14, a coiler can 15 and a sliver coiler 16. The direction of rotation of the various rolls is indicated by respective curved arrows.
Turning to FIG. 2, a flexible bend 17 is secured by screws 18 to the machine frame at opposite sides of the carding machine as also shown in FIG. 7a. The flexible bend has a plurality of setscrews 16 (shown in FIGS. 7a and 10). The flexible bend 17 further has a convex outer surface 17a and an underside 17b. Above the flexible bend 17 a slide guide 20 made, for example, of a low-friction synthetic material is disposed which has a convex outer surface 20a and a concave inner surface 20b. The concave inner surface 20b lies on the convex outer surface 17a of the flexible bend 17 and may slide circumferentially thereon in the direction of the arrows A and B. The flat bars 14 have, at opposite ends, a bar head 14a from which extend a pair of steel pins 14b which slide on the convex outer surface 20a of the slide guide 20 in the direction of the arrow C. A clothing 14d is secured to the underface of the carrier body 14c of the flat bar 14. The points of the clothing 14d of the flat bars 14 lie on an imaginary circle 21. The carding cylinder 4 carries on its circumference a cylinder clothing 4a, such as a sawtooth clothing. The points of the cylinder clothing 4a lie on an imaginary circle 22. The distance between the circles 21 and 22 is designated at a and is, for example, 0.20 mm. The distance between the convex outer surface 20a and the circle 22 is designated at b. The radius of the convex outer surface 20a is designated at r 1 while the radius of the circle 22 is designated at r 2 . The radii r 1 and r 2 intersect the cylinder axis M (FIG. 1).
In the embodiment of FIG. 3 the slide guide 20, forming a first elongated element, is circumferentially shiftable on the flexible bend 17, forming a second elongated element. The distance between the convex outer surface 20a and the concave inner surface 20b (that is, the radially measured thickness) of the slide guide 20 decreases from c 1 to c 2 as viewed in the circumferential direction B whereas the distance between the convex outer surface 17a and the axis M of the carding cylinder 4 increases from d 1 to d 2 as viewed in the circumferential direction B such that c+d is constant at all circumferential locations. To achieve such a relationship, the slide guide 20 and the flexible bend 17 have the shape of a circularly bent wedge which are superposed on one another in oppositely oriented wedge directions. The concave inner surface 20b and the convex outer surface 17a are in sliding contact with one another. The central axis of the convex outer surface 20a coincides with the rotary axis M of the carding cylinder 4. The central axis of the concave inner surface 20b and the convex outer surface 17a, on the other hand, lie externally of the rotary axis M of the carding cylinder 4. It is thus seen that by circumferentially shifting the slide guide 20, it is, by camming action, displaced radially, whereby the radial position of the outer convex supporting surface 20a is altered.
According to the embodiment of FIG. 4, between the concave inner surface 20b of the slide guide 20 and the concave outer surface 17a of the flexible bend 17, forming a second elongated element, an intermediate member 23, forming a first elongated element, is provided which is circumferentially displaceable in the direction of the arrows D and E. The distance between the convex outer surface 20a and the convex inner surface 20b is constant, that is, the slide guide 20 has a constant radial thickness as viewed circumferentially. The distance between the convex outer surface 23a and the concave inner surface 23b of the intermediate member 23 decreases in the circumferential direction D from e 1 to e 2 , whereas the distance between the convex supporting surface 17a and the rotary axis M of the carding cylinder 4 increases in the circumferential direction D from f 1 to f 2 such that e+f is constant at any circumferential location. The axes of the convex outer surface 20a and the concave inner surface 20b coincide with the rotary axis M of the carding cylinder 4, while the axes of the concave inner surface 23b and the convex outer surface 17a lie externally of the rotary axis M of the carding cylinder 4. To achieve such a relationship, the intermediate member 23 and the flexible bend 17 are shaped as oppositely oriented, circularly bent wedges. The concave inner surface 20b and the convex outer surface 23a on the one hand and the concave inner surface 23b and the convex outer surface 17a are in sliding contact with one another. It is thus seen that by circumferentially shifting the intermediate member 23, the slide guide 20 is, by camming action, displaced radially, whereby the radial position of the outer convex supporting surface 20a of the slide guide 20 is altered.
In the embodiment according to FIG. 5, between the concave inner surface 20b of the slide guide 20, forming a first elongated element, and concave outer surface 17a of the flexible bend 17 an intermediate member 23, forming a second elongated element, is provided. The slide guide 20 is displaceable in the circumferential directions A and B and the intermediate member 23 is displaceable in the circumferential directions D and E. The distance between the convex outer surface 20a and the convex inner surface 20b of the slide guide 20 decreases in the circumferential direction A from g 1 to g 2 , while the distance between the convex outer surface 23a of the intermediate member 23 and the rotary axis M of the carding cylinder 4 increases from h 1 to h 2 such that g+h is constant at any location along the circumference. The central axis of the convex outer surface 20a and the central axis of the convex outer surface 17a coincide with the rotary axis M of the carding cylinder 4. The axis of the concave inner surface 20b and the central axis of the concave outer surface 23a lie externally of the rotary axis M of the carding cylinder 4. To achieve such a relationship, the slide guide 20 and the intermediate member 23 are oppositely oriented, circularly bent wedge shape members. The concave inner surface 20b and the convex outer surface 23a are in a sliding contact with one another. It is thus seen that by circumferentially shifting the intermediate member 23 and the slide guide 20, the latter is, by camming action, displaced radially, whereby the radial position of the outer convex supporting surface 20a of the slide guide 20 is altered.
In the embodiment according to FIG. 6, between the concave inner surface 20b of the slide guide 20 and the convex outer surface 17a of the flexible bend 17 two intermediate members 23 and 24 are provided which form first and second elongated elements, respectively. The distance between the convex outer surface 20a and the concave inner surface 20b is constant, similarly to the FIG. 4 embodiment. The intermediate members 23 and 24 are displaceable in the direction D, E and F, G, respectively. The distance between the convex outer surface 23a and the convex inner surface 23b of the first intermediate member 23 increases from i 1 to i 2 , whereas--as viewed in the same direction--the distance between the concave outer surface 24a of the second intermediate member 24 and the rotary axis M of the carding cylinder 4 decreases from k 1 to k 2 such that i+k is constant at each location along the circumference. The axes of the convex outer surface 20a, the concave inner surface 20b and the convex outer surface 17a coincide with the rotary axis M of the carding cylinder 4. The axes of the concave inner surface 23b and the concave outer surface 24a, on the other hand, lie externally of the rotary axis M of the carding cylinder 4. To achieve these relationships, the first and second intermediate members 23 and 24 have the shape of circularly bent wedges which are superposed in an oppositely oriented fashion. The concave inner surface 23b and the concave outer surface 24a are in a sliding contact with one another. It is thus seen that by circumferentially shifting the intermediate members 23 and 24, the slide guide 20 is, by camming action, displaced radially, whereby the radial position of the outer convex supporting surface 20a of the slide guide 20 is altered.
The distances c through k in the embodiments described above in connection with FIGS. 3 through 6 change preferably uniformly as viewed in the circumferential direction.
Turning to FIG. 7a, the flexible bend 17 is provided with a groove 25 having a bottom surface 25a. The slide guide 20 which is made of an elastic, low-friction synthetic material, is, as shown in FIG. 7b, received in the groove 25 such that one part of the slide guide 20 projects beyond the convex outer surface 17a of the flexible bend 17. The slide guide 20 is displaceable within the groove 25 in the direction of the arrows A, B whereby the concave inner surface 20b of the slide guide 20 glides along the bottom surface 25a of the groove 25. The lateral surfaces 25b and the 25c of the groove 25 form lateral guides for the slide guide 20. The functioning of the arrangement of FIGS. 7a and 7b corresponds, for example, to that shown in FIG. 3.
Turning to FIG. 8a, within the groove 25, between the concave inner surface 20b and the bottom surface 25a of the groove 25 a displaceable intermediate member 23 is provided as shown in cross section in FIG. 8b. The arrangement of FIG. 8a and 8b corresponds in function, for example, to the construction shown in FIG. 4.
In FIGS. 9a and 9b the circumferential displacement of the slide guide 20 on the flexible bend 17 is shown to take place in the direction of the arrow A. By means of such a displacement, for example, by a distance of 50 mm, the distance a between the points of the flat bar clothings 14d and the points of the cylinder clothing 4a, that is, the distance between the imaginary circles 21 and 22 is increased from a 1 (for example, 0.30 mm) to a 2 (for example, 0.5 mm). The flat bars 14 are slowly driven in a closed path by a drive belt 13c in the direction C along a working leg from the end roller 13a to the end roller 13b. During the travel along the working leg, the flat bars 14 glide on the slide guide 20 and their clothings 14d cooperate with the clothing 4a of the main carding cylinder 4 in processing the fiber material. At the end of the working leg, the travelling flats 14 are reversed by the roller 13b to travel back, along a return leg, towards the end roller 13a. The radius of the convex outer surface 17a of the flexible bend 17 is designated at r 3 and the radius of the concave inner surface 20b of the slide guide 20 is designated at r 4 . The end rollers 13a and 13b rotate in the direction of arrows H and I, respectively.
Turning to FIG. 10, a toothed rack 27a which is attached to the slide guide 20 by a carrier element 26, meshes with a driving pinion 27b rotatable in the directions O or P. The pinion 27b is driven by a non-illustrated reversible motor to cause the slide guide 20 to be circumferentially shifted in the direction of the arrows A or B.
Turning to FIG. 11, both end portions of the slide guide 20 are flexible and are wound on respective winches 28 and 29 which may be driven by motors 42 and 43 in the direction of the arrows K, L and N 1 , N 2 , respectively.
In the construction shown in FIG. 12 the slide guide 20 is an endless band circulating about support rollers 27, 30, 31, 32 and 33. A reversible motor 44 directly drives the roller 27 selectively in the one or the other direction, whereby the slide guide 20 is circumferentially displaced in the direction of the arrows A or B.
While in the various displacing mechanisms described above in connection with FIGS. 10-12 the displaced component is the slide guide 20, it is to be understood that any of these displacing mechanisms is applicable to the other disclosed displaceable elements, for example, the intermediate members 23 and/or 24.
Turning to FIG. 13, the slide guide 20 is secured at one end to a stationary support 35 with the intermediary of a tension spring 34. By means of the driven end roller 13b of the travelling flats a tension force is imparted on the slide guide 20 in the direction R. Between the slide guide 20 and the flexible bend 17 an intermediate member 23 is provided which is displaceable in the direction of the arrows D or E as shown in FIG. 5.
Turning to FIG. 14, a measuring member 37 such as a NEP CONTROL NCT manufactured by Trutzschler GmbH & Co. KG for the automatic detection of the nep number, a measuring member 38 for detecting the fiber length and a setting member 39 (for example, the drive motor 40) are connected to an electronic control and regulating device 36, such as a microcomputer. The measuring values for the fiber lengths which, for example, may be determined by a fibrograph, may be inputted by an inputting device into the electronic control and regulating device 36. Further, a switching element, such as a pushbutton or the like may be coupled to the electronic control and regulating device 36 with which the motor 40 may be actuated. Further, a measuring member 41 such as a FLATCONTROL FCT, manufactured by Trutzschler GmbH & Co. KG may be connected to the electronic control and regulating device 36 to detect the distance a between the imaginary circles 21 and 22 representing the points of the flat bar clothings 14d and the points of the cylinder clothing 4a, respectively.
Turning to FIG. 15 and also referring to FIGS. 2, 9a and 9b, if the slide guide 20 is shifted from its position shown in FIG. 9a in the direction of the arrow A into the position shown in FIG. 9b, the convex outer surface 20a is displaced in the direction of the arrow U upwardly, so that the radial distance b between the flat bar-supporting surface 20a of the slide guide 20 and the points of the clothing 4a of the carding cylinder 4 increases from b 1 to b 2 . At the same time, the flat bars 14, supported on the slide guide 20 by pins 14b, are also displaced radially upwardly in the direction of the arrow T, so that the distance a between the points of the flat bar clothings 14d and the points of the cylinder clothing 4a increases from a 1 to a 2 . A corresponding decrease of a and b occurs if the slide guide is shifted in the direction B.
It will be understood that the above description of the present invention is susceptible to various modifications, changes and adaptations, and the same are intended to be comprehended within the meaning and range of equivalents of the appended claims. | A carding machine includes a main carding cylinder having a cylinder axis and a cylinder clothing; and traveling flats cooperating with the main carding cylinder along a circumferential length portion thereof. The traveling flats include a plurality of flat bars each having a flat bar clothing cooperating with the cylinder clothing; and a drive for moving the flat bars in unison in an endless path having a working leg in which the flat bar clothings cooperate with the cylinder clothing and a return leg. The working leg extends circumferentially about a portion of the main carding cylinder. The carding machine further has a flexible bend having a convex surface and being supported on the machine frame laterally of the main carding cylinder; and a slide guide supported on the flexible bend. The slide guide has a convex surface supporting the flat bars for sliding motion thereon along the working leg. The radial position of the convex surface of the slide guide relative to the cylinder axis determines the radial clothing point distance between the clothing points of the flat bar clothings and the clothing points of the cylinder clothing. Further, an adjusting device is provided for radially displacing the slide guide such that the radial clothing point distance remains uniform at all locations along the working leg. | 3 |
INCORPORATION BY REFERENCE
[0001] All patents, patent applications and publications cited herein are hereby incorporated by reference in their entirety in order to more fully describe the state of the art as known to those skilled therein as of the date of the invention described herein.
RELATED APPLICATIONS
[0002] This application is a continuation of co-pending U.S. patent application Ser. No. 13/963,190 filed Aug. 9, 2013, which is a continuation of PCT Patent Application No. PCT/US12/24511, filed Feb. 9, 2012, entitled “RECOVERY OF SILICON VALUE FROM KERF SILICON WASTE”, which application claims the benefit of U.S. Provisional Application No. 61/462,905, filed Feb. 9, 2011, entitled “RECOVERY OF SILICON VALUE FROM KERF SILICON WASTE”, the entire content of which are incorporated herein by reference.
BACKGROUND OF THE INVENTION
[0003] The current mainstream method for producing high purity polysilicon for the electronic and photovoltaic (PV) industries is a combination of metallurgical and chemical. Starting from pure quartz (SiO 2 ), metallurgical grade silicon (MG—Si) is made by carbothermic reduction. This material is then converted into trichlorosilane (TCS, SiHCl 3 ) by reaction with HCl gas. After several purification processes via multiple distillations to remove all metallic and nonmetallic impurities present in MG—Si, the purified TCS gas is used to deposit ultra pure polycrystalline silicon. The processes, collectively called the Siemens Process, are very energy intensive.
[0004] The process flow to produce silicon wafers is the following:
MG—Si→TCS→Ultra Purified TCS→PolySi→Crystalline Si→Si Wafer.
[0005] Single or multi crystal silicon is grown from the polysilicon, leading to monocrystalline silicon ingot or multicrystalline silicon block. These are subsequently sliced into thin wafers by a wire saw process. This wire saw process produces significant silicon waste, known as kerf silicon waste, due to the cutting of the silicon ingot or block. While the current wafer thicknesses are in the range 300 microns, the equivalent kerf loss is 200 microns thick. The PV industry intends to reduce the thickness of the silicon wafer to 100 microns by year 2020, which will still cause an equivalent kerf silicon loss of 150 microns per wafer.
[0006] The Semiconductor and Photovoltaic industries produce significant quantities of kerf silicon waste during the wafer manufacturing operation. Slicing silicon ingot or block to make wafers is one of the most expensive and wasteful process steps in the silicon value chain, especially in the PV cell manufacturing industry. Kerf loss amounts to 40% to 50% of the silicon ingot, and which is presently discarded. This adds significantly to the silicon shortage of the PV industry. In addition, substantial amounts of the high purity silicon carbide powder used as abrasive in the wire saw process is also discarded. These waste mixtures end up in landfills. All these contribute to higher PV cell manufacturing costs and wasted energy.
[0007] The table below, based on industry polysilicon estimates and wafer thickness trends, shows the amount of silicon lost as kerf in the process of slicing ingots into wafers.
Quantity of Silicon Kerf Waste, Polysilicon & Market Value
[0008]
[0000]
YEAR
PARAMETER
2011
2012
2013
Total Si Kerf Waste, mT/y
79,000
91,000
100,000
PolySi from Kerf, mT/y
47,000
54,000
60,000
Market Value, $ Billion
2.8
2.7
3.0
[0009] A typical wire saw machine that caters to wafering, e.g., 50 tons of silicon ingots per year, may also require $150,000-$250,000/year for the SiC abrasives and silicon waste disposal costs. The semiconductor and solar industries cannot afford to dispose off such valuable materials without environmental concerns.
[0010] From the wire saw wafering process, large quantities of a slurry consisting of an organic cutting fluid, typically polyethylene glycol (PEG), admixed with the silicon carbide abrasive used for sawing the wafer, material from the saw wire, typically brass-coated iron and steel, and fine silicon powder are formed. The kerf silicon waste or kerf waste comprises the solids left behind after the maximum useable recovery of PEG and SiC from the slurry. Because the kerf is the result of sawing crystal-grown very high purity silicon, it will not have the type or amount of metallic and nonmetallic impurities present in metallurgical grade (MG)—Si. The final kerf silicon residue from the ingot wafer sawing/slurry recycle processes is estimated to be a mixture with only the abrasive SiC and carrier wire, typically Fe with traces of metallic and nonmetallic impurities and the carrier fluid. The particle size of this mixture is in the range 1-20 microns. Typical kerf waste composition is ˜60% Si-35% SiC-5% Fe, 0.1-0.2% Cu and Zn, and traces of metals from the finishing stages of the slurry recovery operation.
[0011] There is no practical process in the industry to recover silicon from the kerf waste and produce high purity silicon at competitive costs. The few development efforts such as the project RE-Si-CLE [ ENK5-CT2001-00567 (2002-04)], iodide transport [PCT/US2009/040261], melt refining [Photovoltaic Specialists Conference, June 2010], etc. are academic in that industrialization is challenging or impractical. Kerf material pretreatment procedures [USPTO Applications 20100163462 and 20100284885] attempt near complete separation of kerf silicon from SiC and metal impurities; however, the Si purity is insufficient for PV applications. The more direct gas phase conversion of kerf silicon waste through TCS and Siemens deposition process [ US Patent Application 20100032630] represents a different approach to very high purity polysilicon.
[0012] Innovative technologies to utilize recoverable sources of polysilicon and produce the right quality feedstock material at the right cost will have a major impact on the photovoltaic industry whose growth demand and growth potential are very dependent on the availability of polysilicon.
SUMMARY
[0013] It is an object of the invention to provide a viable and practical industrial process and technology to recover kerf silicon powder waste into a form that has an appropriate level of purity for use as silicon feed stock for different applications. It is a further object to provide a process and technology that will maintain the intrinsic high purity of the kerf silicon.
[0014] It is another object of the invention to provide a practical process scheme for the recovery and consolidation of the silicon on a commercially useful production level.
[0015] In one aspect, a direct silicon recovery process is provided that recovers the kerf silicon along with the Si content of the associated SiC from the Si+SiC kerf powder mix and the Si is coalesced into a melt which solidifies. The methodology produces usable polysilicon at costs and energy consumption less than by the current methods, while also alleviating or removing the environmentally deleterious kerf silicon disposal.
[0016] The process includes a physico-chemical head-end treatment of the kerf silicon waste material to remove extrinsic metal impurities added during the wire saw and slurry recovery operations. This is followed by a direct metallurgical conversion of the purified kerf waste mix of Si+SiC into silicon.
[0017] High purity silicon is realized from the high quality silicon waste very effectively through a direct metallurgical process that effects the melting of the Si content and reduction of its SiC content to Si. It will produce a very high purity kerf-derived Metallurgical Grade silicon (KMG—Si) product.
[0018] The kerf silicon, apart from the SiC, Fe and a few metallic contaminants (Cu, Zn), is essentially very pure Si in quality, since it was derived from ultra high quality silicon crystal ingot grown from high purity polysilicon. It will have no intrinsic metallic and nonmetallic impurities, and especially no dopant impurities such as B and P. The material will have minor surface oxidation from the slurry recovery process.
[0019] The abrasive SiC in the kerf residue is also of very high purity and is made purer still with the removal of metallic impurities. The other major constituent “impurities” in the SiC abrasive are free carbon, silicon and silica (SiO 2 ). The present process surprisingly takes advantage of these impurities to provide a high purity silicon in an amount greater than the initial silicon present in the kerf waster. These heretofore undesirable “impurities” are all utilized as desirable constituents for the metallurgical silicon recovery process.
[0020] In certain embodiments, the process employs a nominal physical and chemical dissolution process to remove the Fe, Cu, Zn and other metallic impurities from the kerf waste, then utilizes the cleaned kerf material mix of Si and SiC and superficial oxide, to convert to high purity metallurgical silicon in a submerged arc furnace according to well established process. Unlike all reported previous schemes of silicon recovery, there is no need to remove or reduce SiC from the mix. In fact, its presence is advantageous to the kerf refining process.
[0021] Unlike the conventional MG—Si process, the process of this description will need no silica feed or carbon/graphite reductant. The silica equivalent of the SiC needed for the metallurgical reaction is formed in the kerf mix by oxidizing appropriate quantity of kerf Si by exposure to heated air, or less preferably, high purity silica added to the kerf mix. Thus, the typical, major and minor impurity contributions from the silica and reductant are completely eliminated. This helps to maintain the intrinsic purity of the Si from the kerf waste, and provide a product Si of very high purity, free from dopant elements and other metal impurities.
[0022] The metallurgical processes pertinent to the present invention are:
[0000]
BRIEF DESCRIPTION OF THE DRAWING
[0023] This invention is described with reference to the following drawings that are presented for the purpose of illustration only and are not intended to be limiting of the invention.
[0024] The reference process flow sheet to convert kerf waste silicon to processed kerf material for further metallurgical processing is described in FIG. 1 .
[0025] A process scheme according to one or more embodiments of the present invention to convert processed kerf silicon with in-situ silica formation to high purity kerf-derived Metallurgical Grade silicon (KMG—Si) is shown in FIG. 2 .
[0026] A process scheme according to one or more embodiments of the present invention to convert processed kerf silicon with added silica to high purity kerf-derived Metallurgical Grade silicon (KMG—Si) is shown in FIG. 3 .
[0027] A process flow sheet of the present invention to process high purity kerf-derived Metallurgical Grade silicon (KMG—Si) to solar grade silicon through metallurgical route is shown in FIG. 4 .
[0028] A process flow sheet of the present invention to process high purity kerf-derived Metallurgical Grade silicon (KMG—Si) to solar grade silicon through trichlorosilane route is shown in FIG. 5 .
DETAILED DESCRIPTION
[0029] The challenge in recycling the kerf silicon is to produce silicon of the required purity, cost and environmental impact compared with current feedstock production. The most practical process for the silicon recovery is to recycle the material to the beginning of the Si process cycle (MG—Si formation) where it will integrate seamlessly with established industrial and logistical operations. With the high intrinsic purity of the kerf Si and SiC, it can be guaranteed that the silicon product from such a kerf-recovery process will be immensely higher in purity than any level that can be achieved from the currently practiced MG-silicon process.
[0030] The metallurgical route is a process technology very well practiced by the industry for >50 years. If such a process can be appropriately adapted to utilize the kerf silicon waste, the recovered silicon will make a very significant contribution to the PV feedstock industries from material quantity and material cost saving.
[0031] In one aspect, a method of converting kerf silicon waste to high purity kerf-derived Metallurgical Grade silicon includes providing a kerf silicon waste comprising silicon (Si) and an abrasive reducing agent selected from the group consisting of silicon carbide, carbon and mixtures thereof; introducing to the kerf silicon waste a desired amount of silicon oxide in proportion to the amount of abrasive reducing agent in the kerf silicon waste to provide a kerf material mixture; treating the kerf material mixture to reduce the silicon oxide to silicon and thereby consume the reducing agent in the kerf material mixture and provide a kerf-derived Metallurgical Grade silicon.
[0032] In one or more embodiments, the further include separating additional impurities from the kerf silicon waste using one or more of the following processes:
[0033] reducing a carrier fluid from the kerf silicon waste;
[0034] reducing metallic impurities from the kerf silicon waste; and
[0035] washing and drying the kerf silicon waste.
[0036] In one or more embodiments, the carbon content of the kerf-derived Metallurgical Grade silicon is less than 100 ppm.
[0037] In one or more embodiments, the silicon oxide includes silica.
[0038] In one or more embodiments, introducing to the kerf silicon waste a desired amount of silicon oxide includes one or more of the following:
[0039] oxidizing a portion of the silicon content of the kerf material mixture to silicon oxide; and/or
[0040] adding a high purity SiO 2 to the kerf material mixture.
[0041] In one or more embodiments, the kerf silicon waste includes high purity silicon, residual wire saw slurry, and wire saw material.
[0042] In one or more embodiments, the residual wire saw slurry includes a liquid carrier and the abrasive reducing agent.
[0043] In one or more embodiments, the liquid carrier is selected from the group consisting of polyethylene glycol, water and oil and mixtures thereof.
[0044] In one or more embodiments, the residual wire saw material is selected from the group consisting of iron, steel, stainless steel, brass coated iron and brass coated steel and combinations thereof.
[0045] In one or more embodiments, separating the kerf silicon waste includes washing with high purity water to remove water soluble impurities of the kerf silicon waste.
[0046] In one or more embodiments, separating the kerf silicon waste includes washing the kerf silicon waste from oil-based carrier fluid wire saw process with an organic-based liquid extractant to remove oil.
[0047] In one or more embodiments, magnetic metallic impurities in the kerf silicon waste are reduced by a magnetic separation system.
[0048] In one or more embodiments, metallic impurities in the kerf silicon waste are reduced by treating with acid mix to dissolve the metals.
[0049] In one or more embodiments, the conversion of kerf material mixture to kerf-derived Metallurgical Grade silicon is carried out through a metallurgical reduction process.
[0050] In one or more embodiments, the metallurgical reduction process is performed primarily in an electric arc furnace.
[0051] In one or more embodiments, the metallurgical reduction process is performed at temperatures in the range 1500 C to 2000 C.
[0052] In one or more embodiments, the metallurgical reduction process produces kerf-derived Metallurgical Grade silicon having a purity of greater than 99.9 wt % Si.
[0053] In one or more embodiments, the metallurgical reduction process produces kerf-derived Metallurgical Grade silicon having a purity of greater than 99.99 wt % Si.
[0054] In one or more embodiments, the kerf-derived Metallurgical Grade silicon includes dopant levels of less 1 ppm for Boron and less than 1 ppm for Phosphorus.
[0055] In one or more embodiments, the kerf-derived Metallurgical Grade silicon is further refined using a directional solidification process.
[0056] In one or more embodiments, kerf-derived Metallurgical Grade silicon includes less than 1 ppm of any impurity.
[0057] In one or more embodiments, the method further includes reacting the kerf-derived Metallurgical Grade silicon to form trichlorosilane using a process selected from the group consisting of hydrochlorination and chlorination and combinations thereof.
[0058] In another aspect, a method of making a silicon wafer includes:
[0059] providing a kerf-derived silicon ingot prepared as described herein; and
[0060] cutting a wafer from the ingot, wherein a wafer is obtained without an additional melt and crystal growth step.
[0061] As used herein “high purity” silicon and “high purity” silica refers to materials having less than 1 ppm of any impurity.
[0062] As used herein “metallurgical grade” silicon refers to materials having less than 1% impurities.
[0063] As used herein “silicon oxide” refers to a oxygen-containing silicon having a range of oxygen, e.g., SiO x . In preferred embodiments, the silicon oxide is silicon dioxide (SiO 2 ),which provides a known oxygen level in the kerf silicon mixture.
[0064] With reference to FIG. 1 , the basic steps of a preferred method for the kerf recovery process are as follows: The kerf silicon waste, contaminated with SiC, Fe, trace metallic and nonmetallic impurities, polyethylene glycol (PEG) and water is washed with high purity water to remove PEG. The wash system, which can be co-current or counter current column type or other, will incorporate a magnetic separator to remove most of the elemental Fe impurity from the kerf waste. The resulting water-based slurry, which will contain SiC, Si and traces of metallic and nonmetallic impurities will be put through an acid wash at ambient temperature. The purpose of this step is to dissolve traces of extrinsic metallic impurities from the kerf mix. The wash acid is preferably a mix of hydrochloric acid to enable the dissolution of iron, zinc and other metals, and nitric acid to oxidize metals such as copper to enable their dissolution. The slurry, after the acid wash, is filtered and washed with clean water to provide a clean wet cake of silicon with 20-40% SiC and free of metallic and nonmetallic impurities. The cake is dried at 150°-200° C. in a clean air environment to produce a dry cake of the same.
Conversion of Kerf Si+Sic Mix To High Purity Kerf-Derived Metallurgical Grade Silicon (Kmg—Si)
[0065] Industrially, metallurgical silicon is manufactured by reduction of silica (SiO 2 ) with carbon in a submerged electrodes arc furnace. The overall metallurgical reaction is
[0000] SiO 2 ( s )+2C ( s )=Si( l )+2CO ( g ). [3].
[0066] The process, however, occurs in complex multistages at different hot zones of the arc furnace (reactions [4] through [8]).
[0067] Liquid silicon is produced in the inner hot zone, where the temperature is 1800°-2100° C., according to the following chemical schemes:
[0000] SiO 2 ( s )+3C( s )=SiC( s )+2CO( g ) [4]
[0000] 2SiO 2 ( l )+SiC( s )=3SiO ( g )+CO( g ) [5]
[0000] SiO( g )+SiC( s )=2Si( l )+CO( g ) [6].
[0068] The high temperature in the inner zone allows formation of a high proportion of SiO (g) in this zone according to reaction [5]. High partial pressure of SiO (g) is indispensable for the formation of Si (l) according to reaction [6].
[0069] In the outer zone, where the temperature is below 1800° C., SiO (g) emanating from the inner zone encounters and react with free carbon to form SiC (s) according to reaction [7]. The SiO (g) also undergoes disproportionation reaction according to reaction [8]. The silicon carbide SiC (s) and Si (l) forms in a matrix of SiO 2 (s,l).
[0000] SiO( g )+2C( s )=SiC( s )+CO( g ) [7]
[0000] 2SiO( g ) Si( l )+SiO 2 ( s ) [8].
[0070] Thus, SiC is an important intermediate in the metallurgical reduction process of converting SiO 2 into Si. While the overall pertinent reaction for the present invention is
[0000] SiO 2 ( s )+2SiC ( s )=3Si ( l )+2CO ( g ). [9].
[0071] The mix of Si+SiC+SiO 2 , therefore, provides multiple reaction paths for the formation of the critical SiO (g) from high temperature equilibria of reactions [5] and [8]. In addition, the melting of Si from the mix will also result in material porosity that enables the SiO (g) to diffuse, migrate and react with SiC (s) to form Si (l).
[0072] Thus, confining the reduction of SiO 2 by SiC according to reaction scheme [9] is a much more efficient process with relatively lower emission of gaseous species per silicon equivalent compared to the conventional reduction of SiO 2 with carbon, reaction [3]. If the concentration of SiO 2 is kept high, the silicon carbide content of the mix can be completely eliminated, thus lowering the carbon contamination in the formed Si.
[0073] The present invention will utilize the SiC impurity in the kerf waste and reaction [9] to efficiently recover the Si from the kerf waste. The kerf silicon recovery process, thus, is a total process to recover the silicon values from its Si and SiC contents. It also requires significantly less electrical energy for the overall Si recovery process, from typically 13 kWh/kg Si for regular MG—Si production to ˜6 kWh/kg for 50% Si+50% SiC mix and ˜2 kWh/kg Si for 90% Si+10% SiC mix (with appropriate equivalent added SiO 2 ).
[0074] Two process methodologies are described. The first process involves in-situ creation of SiO 2 equivalent in molar concentration to the SiC content of the kerf waste, which is illustrated in the process flow diagram in FIG. 2 .
[0075] In this process, a part of the silicon content of the purified kerf mix will be oxidized at high temperature to form controlled amount of SiO 2 . At the end of this process the kerf mix contains Si+SiC+formed amount of SiO 2 .
[0076] Table 1 gives the theoretical quantity of Si to be oxidized for equivalency to the SiC content.
[0000]
TABLE 1
In-Situ Oxidation of Silicon
Total Si + SiC Weight 100 kg
SiO 2
Si equiv. to
Total Si
Si
SiC
needed
oxidize
formed
kg
kg
kg
kg
kg
100
0
0.0
0
100.0
90
10
7.5
3.5
97.0
80
20
15.0
7.0
94.0
70
30
22.5
10.5
91.0
60
40
30.0
14.0
88.0
50
50
37.5
17.5
85.0
40
60
45.0
21.0
82.0
30
70
52.4
24.5
79.0
26
74
55.4
25.9
77.8
[0077] The second process involves the addition of pure SiO 2 equivalent to the SiC content, as is illustrated in the process flow diagram of FIG. 3 .
[0078] In this process, quantified amount of high purity SiO 2 will be added to the purified kerf mix, rather than oxidizing a quantity of the silicon in the kerf mix. At the end of this process the kerf mix will contain Si+SiC+added amount of SiO 2 .
[0079] Table 2 gives the quantity of SiO 2 to be added for equivalency to the SiC content.
[0000]
TABLE 2
Add SiO 2
Total Si + SiC Weight 100 kg
Si equiv of
Total Si
Si
SiC
SiO 2 to add
SiO 2
formed
kg
kg
kg
kg
kg
100
0
0.0
0
100.0
90
10
7.5
3.5
100.5
80
20
15.0
7.0
101.0
70
30
22.5
10.5
101.5
60
40
30.0
14.0
102.0
50
50
37.5
17.5
102.5
40
60
45.0
21.0
103.0
30
70
52.4
24.5
103.6
26
74
55.4
25.9
103.8
[0080] Method 1 intrinsically maintains the high purity nature of the kerf waste containing Si+SiC+SiO 2 . The quality of the SiO 2 added to the kerf waste in Method 2 requires it to be >99% pure to ensure high purity for the resulting kerf-derived Metallurgical Grade silicon.
[0081] Methods 1 and 2 may be combined to supplement SiO 2 to the desired level if required.
[0082] With either method it is recommended to use a nominal 5-10 weight percent excess of the silica content with respect to the SiC stoichiometry in the (Si+SiC+SiO 2 ) mix to ensure complete reaction of the SiC with SiO 2 in the arc furnace process. This will ensure carbon content in the formed liquid silicon to no more than the saturation limit of approximately 35 ppmw.
[0083] In some embodiments, the SiO 2 content (and the content of SiC), e.g., Si, O and C content, can be determined prior to metallurgical processing. Further adjustments can be made to the SiO 2 just prior to metallurgical processing to ensure that sufficient SiO 2 is present.
[0084] With either method, the material is to be mixed well to homogenize the ingredients prior to use as a feed to the arc furnace. While the mix powder is an appropriate feed to the arc furnace, the mix may be formed into briquettes, granules or pellets for ease of material loading and to provide uniform distribution of the three component (Si+SiC+SiO 2 ) solid material to the hot zone for efficient reaction.
[0085] The purity of the kerf-derived Metallurgical Grade silicon (KMG—Si) from the process will be >99%, even >99.99% if the kerf material is cleaned from extrinsic impurities. The level of dopants (B+P) would also be <1 ppmw. If untreated (except for bulk Fe removal) kerf material is utilized, the product Si material purity is expected to be >98%, even >99.7%, with <1 ppmw dopant impurities.
[0086] The silicon product from the process of this invention is expected to have a material purity suitable for use as highly upgraded Metallurgical Grade silicon. With a nominal melt refining process, such as melting in oxidic crucible and directional solidification casting, the silicon will be suitable for direct use as PV feedstock.
[0087] In other processes, abrasive carbons such as diamond are used in the wafering process. Carbon abrasive can be used as the abrasive reducing agent in processes similar to those described above, relying for example, on reduction pathways such as described in [4]. It will be appreciated that the silicon yield will be lower in that the abrasive carbon is not a silicon source.
Example 1
Pretreatment of Kerf Silicon
[0088] Kerf silicon typically contains 50-60% Si, 25-30% SiC, 5-10% oxidized Si, 4-5% Fe, approximately 0.1% Cu and Zn and traces of other metallic impurities added from the slurry recovery and kerf silicon separation processes. Typical levels of impurities in kerf Si are: Fe ˜4-5%, Al 250-300 ppm, Ca 500-700 ppm, Ti 50-100 ppm,
[0089] Mn 100-200 ppm, Na 0.1%, Cu ˜0.2%, Zn ˜0.1%, traces of alkali metals.
[0090] B<2 ppm, P ˜0 ppm. Almost all of these impurities are extrinsic to the silicon, since the latter was derived from crystal grown ingots. As such, the levels of these impurities can be controlled and reduced by proper care in the slurry recovery and kerf separation processes. They can also be removed by appropriate pretreatment of the kerf silicon waste.
[0091] Since these impurities are present as metals or their oxides, acid extraction is the most appropriate pretreatment process. In an example the kerf silicon was treated by leaching the impurities with a dilute acid mix of HCl and HNO 3 , and washed with DI water. The total residue from this process (Si+SiC+Oxidized Si) analyzed the following: Fe 100 ppm, Cu 120 ppm, Zn 20 ppm, Al 50 ppm, Ca 20 ppm, and alkali metals 500 ppm, with leaching efficiencies in the range 80% to >95% . Typically the process is reactive mass transfer from the pores of the kerf silicon waste powder into the leachant solution and the reduction of the impurities can be considered to depend upon the number of acid leach treatments. As such, multiple pretreatment washes are expected to provide a treated kerf silicon material with extrinsic impurities such as Fe<1 ppm, Cu<0.5 ppm, Zn<0.1 ppm, Al<1 ppm, and transition metals <1 ppm. Such acid treatments are not expected to reduce the intrinsic impurities contained in the Si or SiC of the treated kerf silicon material.
Comparison of Pretreated Kerf-Derived Mg-Silicon (Kmg—Si) With Commercial Mg—Si (Mg—Si) And Upgraded Mg—Si (Umg—Si)
[0092] The metallic impurity content of such pretreated kerf silicon is significantly better than that of MG—Si and UMG—Si. MG—Si material is typically 98% -99% pure., with levels of impurities: Fe 1550-6500 ppm, Al 1000-4350 ppm, Ca 245-500 ppm, Ti 140-300 ppm, C 100-1000 ppm, O 100-400 ppm, B 40-60 ppm, P 20-50 ppm and traces of such impurities as Mn, Mo, Ni, Cr, Cu, V, Mg and Zr. The target composition for the UMG—Si is typically Fe<150 ppm, Al<50 ppm, Ca<500 ppm, Cr<15 ppm, Ti<5 ppm, B<30 ppm and P<15 ppm. Secondarily purified UMG—Si has Fe<50 ppm, Al<50 ppm, Ca<50 ppm, Ti<5 ppm, B<7 ppm and P<7 ppm.
[0093] In comparison, the metal contents of the pretreated kerf silicon, not including in its SiC content, are generally <1 ppm for most typical metals, and with dopant levels of <0.2 ppm for B and ˜0 ppm for P.
[0094] The SiC normally used for the wire saw process is the high purity type. It typically analyses >99.3% SiC, free Si 0.2%, SiO 2 0.3%, free C 0.1%, Fe 0.05%, Al 0.01% and Ca 0.01%. In its manufacturing process SiC will not contain any phosphorous impurity. High purity SiC does not contain any significant quantity of boron, another potential silicon dopant element. In the arc melt metallurgical process such boron impurity, if it is contained in the SiC, will end up mostly in the metallurgically formed silicon. The overall boron level in such formed silicon, however, can be controlled to the desired level by appropriately choosing the percentage of such SiC in the mix with the intrinsically pure silicon and oxidized silicon. The boron level in the kerf-derived Metallurgical Grade silicon (KMG—Si) will also be reduced in a subsequent directional solidification purification process.
[0095] It is anticipated that the silicon from the arc melt processing of the mix of pretreated kerf silicon, SiC and composition-adjusted SiO 2 will have most metallic impurities of the order of low 1-2 ppm, Fe ˜100-150 ppm, Al ˜25 ppm and Ca ˜25 ppm, and with dopant impurities of B<0.5 ppm and P ˜0 ppm. Further purification of this material by a controlled directional solidification (DS) process is expected to provide solar grade Si with purities >99.9995%, with B<0.3 ppm, a level acceptable for solar grade silicon.
Refining The Silicon From Pretreated And Submerged Arc Melted Kerf-Derived Metallurgical Grade Silicon (Kmg—Si)
[0096] Significant purification of the silicon material would occur during the directional solidification process ( FIG. 4 flow sheet) since the solid to liquid partition coefficients for the metallic impurities are: >10 −5 for Ti, V, Cr, Fe, Co, Ni, Zn, Zr, Nb, Mo, Ta, W, etc, >10 −4 for Cu, >10 −2 for Al, etc. Such levels of decontamination can be achieved in typical Czochralski (CZ) crystal growth process for silicon. The effective partition coefficients in industrial DS process have values typically of the order of >10 −3 . Even such values will provide decontamination factors for the kerf-derived Metallurgical Grade silicon (KMG—Si) with a single directional solidification process with metal impurities of <1 ppm.
[0097] Only limited purification is possible for non metals such as O, C, B and P in the directional solidification process. P is not pertinent since the pretreated kerf silicon does not have this impurity. Any trace impurity of P, if present in the kerf silicon or SiC, will also be removed in the arc melt process of forming KMG—Si. The level of boron in the kerf-derived Metallurgical Grade-Silicon (KMG—Si) material is expected to be <0.5 ppmw, which will result in a DS processed silicon with boron impurity of <0.3 ppmw (for boron partition coefficient of 0.8).
[0098] It should be noted that the DS step will not only purify the silicon but also transforms its crystal structure from polysilicon to multicrystalline silicon.
[0099] The use of the directional solidification process as a means to further reduce impurity levels thus creates the opportunity to streamline downstream operations for the production of solar cells. The PV industry uses polysilicon chunks or granules too melt and grow silicon ingots or blocks that are then sawn into wafers for subsequent processing. As mentioned previously, multicrystalline silicon blocks are grown using the DSS process. Since the PV silicon manufacturing of the present invention already incorporates the DSS step, another downstream melt and growth of silicon blocks is typically unnecessary. Hence, the silicon product, produced by this invention can bypass the ingot growth step and is thus suitable for wafering operations.
Variations Of The Present Invention
[0100] Although the present invention refers to kerf silicon waste from PEG-based wire saw process that utilizes SiC abrasive, the process is adaptable to other wire saw processes, such as with use of SiC or diamond abrasive in oil- or water-based systems. In such cases the residual oil from the kerf silicon waste can be extracted with an organic extractant, followed by the process scheme described in this invention. The diamond residue will not need to be separated from the silicon, since it acts as a source of carbon for the metallurgical reduction process.
[0101] Even higher purity KMG—Si is possible by reducing the amount of SiC in the treated kerf mix that is fed into the arc furnace and thus taking advantage of the intrinsic high purity of the silicon powders to the greatest extant possible.
[0102] This invention is also applicable to silicon lost in the backgrinding and chemical mechanical polishing steps on semiconductor and PV wafers.
[0103] While this invention describes a method to convert kerf silicon to solar grade silicon by a combination of a submerged arc melt process followed with a single DSS process, the silicon material from the arc melt process is also applicable for hydrochlorination with HCl gas or chlorination with SiCl 4 and H 2 gases to form trichlorosilane ( FIG. 5 flow sheet). The purity of such trichlorosilane before further processing will be significantly better than the currently produced material. This will make it feasible to reduce the number of distillation stages to produce high purity solar grade polysilicon or very high purity electronic grade polysilicon.
[0104] While the process of this invention will utilize conventional submerged arc furnaces with carbon electrodes, other high temperature furnace systems such as with induction heating, etc. may be practical for the type of reaction feed to produce silicon.
[0105] Other and various embodiments of the methodology described in this invention will be evident to those skilled in the art from the specification of this invention. | The present invention is for the recovery of maximum silicon value of kerf silicon waste, produced during the manufacture of silicon wafers by wire saw, diamond saw and chemical mechanical polishing, as high purity metallurgical silicon. This recovery is achieved by a process scheme that effects an initial removal of minor extrinsic metallic impurities but not the major silicon compound impurities, and followed, preferentially, by a direct metallurgical process to form elemental silicon. The recovered silicon is for use as feedstock for polysilicon manufacturing, as high purity polysilicon for PV application, and in metallurgical alloy manufacture. | 2 |
BACKGROUND
[0001] The invention relates generally to medical imaging systems, and more particularly to a composite structure for use in a magnetic resonance imaging system and a method of manufacturing the same.
[0002] The vacuum vessel of an MRI magnet is generally made of components that are welded together during assembly of the magnet to form a pressure boundary. Therefore, the function of the vacuum vessel of an MRI magnet is to provide a reliable pressure boundary for maintaining proper vacuum operation. Any leakage or gas permeation over time will increase the vacuum pressure and, consequently, increase the heat load of the magnet.
[0003] Vacuum vessels known in the art are usually made of metals such as stainless steel, carbon steel and aluminum. Although, metal vacuum vessels are strong enough to resist vacuum forces, they generate eddy currents and unwanted field distortions in the imaging volume when exposed to an AC field.
[0004] Attempts have been made to construct non-metallic vacuum vessels. However, non-metallic vacuum vessels tend to be permeable to gasses and moisture, which hampers the normal vacuum operation.
[0005] Similarly, attempts have been made to use thin metallic foils over the non-metallic vacuum composite structures for providing vapor barrier. One major disadvantage with such composite structures is that the metallic foils may not seal properly at the flange joints of the vacuum composite structures.
[0006] Thus, there is a need for an impermeable vacuum composite structure that provides reduced field effects from eddy currents.
SUMMARY
[0007] In accordance with one aspect of the present technique, a composite sealed vessel is provided. The vessel includes a non-metallic, generally cylindrical inner containment piece, a non-metallic, generally cylindrical outer containment piece disposed around the inner containment piece. A pair of non-metallic flanges are disposed at ends of the inner and outer containment pieces to form a closed structure defining a cavity therein. The vessel also includes a metallic external lining disposed over the closed structure to form a leak-tight pressure boundary. A method for manufacturing the composite sealed vessel is also provided. Further, a system for reducing eddy current losses in a magnetic resonance (MR) system is also provided.
[0008] In accordance with another aspect of the present technique, a composite sealed vessel is provided. The composite sealed vessel includes a non-metallic inner containment piece, and two non-metallic flanges coupled to the edges of the inner containment piece to form a composite structure having a cavity therein. An external lining is disposed over the composite structure to form a closed composite structure having a leak tight pressure boundary for maintaining a vacuum pressure within the cavity, wherein the external lining comprises thin metallic sheets welded over the inner containment piece and the two flanges, and a thick metallic sheet forming an outer containment piece.
[0009] These and other advantages and features will be more readily understood from the following detailed description of preferred embodiments of the invention that is provided in connection with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0010] FIG. 1 is a perspective view of a magnet assembly in accordance with aspects of the present technique;
[0011] FIG. 2 is a cross-sectional view of the magnet assembly of FIG. 1 taken along line II-II of FIG. 1 ;
[0012] FIG. 3 is an exploded view of an outer shell (vessel) of the magnet assembly of FIG. 1 in accordance with aspects of the present technique;
[0013] FIG. 4 is a cross-sectional view of an alternative embodiment of the outer shell (vessel) taken along line II-II of FIG. 1 in accordance with aspects of the present technique;
[0014] FIG. 5 is an exploded view of an alternative embodiment of an outer shell for use in a magnet assembly in accordance with aspects of the present technique;
[0015] FIG. 6 is a diagrammatic view of a horizontally-oriented superconducting magnet in accordance with aspects of the present technique;
[0016] FIG. 7 is a diagrammatic view of a vertically-oriented superconducting magnet in accordance with aspects of the present technique;
[0017] FIG. 8 is a diagrammatic representation of a closed MR system illustrating a superconducting magnet assembly disposed within the MR system in accordance with aspects of the present technique; and
[0018] FIG. 9 is a diagrammatic representation of an open MR system illustrating a superconducting magnet assembly disposed within the MR system in accordance with aspects of the present technique.
DETAILED DESCRIPTION OF EXEMPLARY EMBODIMENTS
[0019] In the subsequent paragraphs, an approach for manufacturing a superconducting magnet assembly will be explained in detail. The approach described hereinafter produces a superconducting magnet structure with reduced eddy current and eddy current induced magnetic field, such as for motors, generators, power superconducting magnetic energy storage applications, and magnetic resonance (MR) applications, including nuclear magnetic resonance spectroscopy (NMR) applications, magnetic resonance imaging (MRI) or magnetic resonance spectroscopy. The various aspects of the present technique will be explained, by way of example for an exemplary MR application, with the aid of figures hereinafter. Although the present techniques will be explained with reference to an MR application, it should be appreciated that the teachings of the present techniques may be applied to other applications where AC losses need to be contained for efficient operation.
[0020] Referring generally to FIG. 1 , manufacturing techniques will be described by reference to a magnet assembly designated generally by numeral 10 . The magnet assembly 10 includes an outer shell (vessel) 12 surrounding a bore 14 . As will be appreciated by those skilled in the art, in an imaging application, a subject is placed in the bore 14 for imaging. Thus, the bore 14 provides access to the imaging volume for a subject. The outer shell 12 includes an outer lining 16 , an inner lining 18 , and two annular end lining flanges 20 and 22 . The outer lining 16 , inner lining 18 , and the two annular end lining flanges 20 and 22 together form a closed composite structure that encloses an evacuated volume as described below.
[0021] Referring now to FIG. 2 , a cross-sectional view of the magnet assembly 10 of FIG. 1 taken along line II-II of FIG. 1 , is illustrated. As illustrated, the magnet assembly 10 includes the outer shell 12 surrounding the bore 14 . The outer shell 12 is constructed to enclose a vacuum volume or a vacuum cavity 24 . Within the vacuum cavity 24 , a superconducting magnet assembly 26 is disposed. The outer shell 12 is constructed by disposing a composite outer cylinder 28 over a composite inner cylinder 30 in a concentric fashion. The composite outer cylinder 28 and the composite inner cylinder 30 are closed via two annular flanges 32 and 34 , to form a closed composite structure. The composite outer cylinder 28 , the composite inner cylinder 30 , and the two flanges 32 and 34 may be made of a plastic or fiber material, such as but not limited to, a fiberglass material, a ceramic material, or a synthetic plastic material. Therefore, the two flanges 32 and 34 may be either thermally fused together or even separably joined with the composite outer cylinder 28 and the composite inner cylinder 30 at corners shown generally by reference numeral 36 .
[0022] The closed composite structure thus formed is then surrounded and sealed by thin metallic sheets that form an external lining over the closed composite structure. An outer metallic lining 16 is disposed proximate to the composite outer cylinder 28 , while an inner metallic lining 18 is disposed proximate to the composite inner cylinder 30 . Two annular end linings 20 and 22 are disposed proximate to the flanges 32 and 34 , respectively. The outer metallic lining 16 , the inner metallic lining 18 , and the two annular end linings 20 and 22 may be made of metal, such as stainless steel, carbon steel, or aluminum. These components 16 , 18 , 20 , and 22 may be welded together at the edges, as designated generally by reference numeral 38 . Thus, the outer shell 12 is a sealed vacuum vessel enclosing the vacuum volume 24 , which withstands vacuum forces shown generally by arrows 40 .
[0023] It may be noted that the magnetic field of MR magnet and gradient assembly 10 , particularly important within bore 14 , is less influenced to a large extent by metallic lining at the outer periphery 16 . Therefore, the outer metallic lining 16 may be thicker than the inner metallic lining 18 . The metallic lining at the outer periphery 16 is further away from the gradient coil and the imaging volume 14 , and therefore is exposed to smaller gradient pulsing field, causing smaller field disturbance in the imaging volume 14 . The thickness of the metallic lining depends upon the particular application, however, and is therefore a matter of design choice. The thickness of the metallic lining is determined by the eddy current skin-depth, which permits the lower frequency fields to penetrate through the sheet, while reflecting the higher frequency fields. The actual cut-off frequency is determined by the resistivity of the material and its thickness. For example, the various metallic lining elements, for this MR magnet assembly 10 , may be of a thickness of the order of a fraction of a millimeter of stainless steel for the inner metallic lining 18 , and 1 to 2 millimeter of stainless steel for the outer metallic lining 16 . This thickness allows lower frequency fields, of less than about 100 Hz, to pass through.
[0024] Similarly, in various other applications, the design frequency cut-off depends on the particular application. For example, in a motor or generator this frequency may be about 100 Hz to about 500 Hz; for a power superconducting magnetic energy storage application, from about 500 Hz to about 5 kHz; and, for a nuclear magnetic resonance spectroscopy (NMR) system, the range may be between about 2 kHz and about 10 kHz.
[0025] The superconducting magnet assembly 26 is disposed within the outer shell 12 in the vacuum volume 24 via mechanically support structures that are not shown for clarity. The superconducting magnet assembly 26 includes a composite bobbin-shaped structure 42 , which includes a plurality of recesses 44 . The composite bobbin 42 may be made of thermally conductive strands, such as copper, that may be co-wound, intertwined, with fiberglass strands and reinforced with, but not limited to, epoxy to form a composite body.
[0026] In each of the recesses 44 , is disposed a superconducting coil 46 , which may be made of a coil of metallic or ceramic wires, such as of Niobium-Titanium wires. The superconducting coil 46 wound in each recess 44 may be interlinked with that disposed in another proximate recess 44 , via electrical couplers or jumpers. A cryogenic coil 48 is wound or disposed over the composite bobbin 42 , such that the cryogenic coil 48 is proximate to the composite bobbin 42 in locations not including the recesses 44 .
[0027] As previously described, the superconducting coil 46 is wound in the recesses 44 of the composite bobbin 42 . Each segment of the superconducting coil 46 disposed in each recess 44 may be disposed over an insulating liner 50 that prevents the superconducting coil 46 to be electrically coupled to the composite bobbin 42 . The insulating liner 50 may be an epoxy liner, or other electrically insulating material. It may be noted that the wires of the superconducting coil 46 may also be coated with an insulating material. The structure thus formed is coated with a potting material 52 that forms a uniform overlayer. Leads of the superconducting coil 46 , shown generally by reference numeral 54 , and conduits of the cryogenic coil 48 , shown generally by reference numeral 56 , may be conducted out of the potting 52 for electrical coupling with magnet operation control circuitry and cryogen feed mechanism (not shown), respectively.
[0028] Turning now to FIG. 3 , an exploded view of an outer shell 12 of the magnet assembly 10 of FIG. 1 is shown. As illustrated, the outer shell 12 includes a composite outer cylinder 28 and a composite inner cylinder 30 that are arranged concentric to each other with respect to their central axes. Two annular flanges 32 and 34 are arranged axially to the composite cylinders 28 and 30 , such that the annular flanges 32 and 34 and the composite cylinders 28 and 30 together form the closed composite structure enveloping an annular inner volume. It may be noted that the diameter of the composite outer cylinder 28 , and the outer diameters of the annular flanges 32 and 34 are the same. Similarly, the diameter of the composite inner cylinder 30 , and the inner diameters of the annular flanges 32 and 34 are the same.
[0029] A thin outer metallic lining 16 having diameter substantially equal to the outer diameter of the composite outer cylinder 28 is arranged radially over the composite outer cylinder 28 . Another thin inner metallic lining 18 having diameter substantially equal to the inner diameter of the composite inner cylinder 30 is also arranged radially within the composite inner cylinder 30 . These metallic linings 16 and 18 are then welded together with two annular end linings 20 and 22 , which are also arranged axially to the metallic linings 16 and 18 . As noted above, the outer metallic lining 16 may be thicker than the inner metallic lining 18 . Moreover, welding of these metallic sheets 16 , 18 , 20 , and 22 ensures the outer shell thus formed to be vacuum-sealed. Because the metallic sheets alone are not sufficiently strong to withstand the forces resulting from the pressure difference across the vessel wall when a vacuum is drawn within the vessel, the underlying composite material provides the necessary strength. At the same time, the lining provides an air-tight boundary to prevent leakage into the vessel through the composite material. The use of thin metal reduces the influence of AC fields on the overall structure.
[0030] FIG. 4 is a cross-sectional view of an alternative embodiment of an outer shell 58 for use in the magnet assembly of FIG. 1 . As illustrated, the outer shell 58 includes a composite inner cylinder 30 , and an outer metallic cylinder 60 . The composite inner cylinder 30 and the outer metallic cylinder 60 are joined using annular flanges 32 and 34 . An inner lining 18 , two annular metallic linings 20 and 22 are then welded together at the joints or corners 38 . The outer shell thus formed includes a bore 14 , as shown. Although, the outer cylinder 60 is made of a metal, the metal cylinder is less influenced by AC fields superimposed on the strong magnetic field generated by the superconducting magnet assembly 26 that is disposed within the vacuum cavity 24 . This is because the magnetic field is directed towards the centre into the bore. The outer cylinder 60 is thus relatively spaced from the more important portion of the field.
[0031] Referring generally to FIG. 5 , an exploded view of an alternative embodiment of an outer shell 62 for use in a magnet assembly is shown. The outer shell 62 is constructed using a composite cylinder 64 , which is joined together via two flanges, an upper composite flange 66 , and a lower composite flange 68 . The composite cylinder 64 and the composite flanges 66 and 68 may be made of a fiber or plastic material, such as fiberglass, ceramic, or plastic. These components 64 , 66 , and 68 may be thermally fused or joined to form a closed pancake-shaped structure. A thin metallic outer lining 70 having an inner diameter substantially equal to the outer diameter of the composite cylinder 64 is then welded with two metallic discs, an upper metallic lining 72 and a lower metallic lining 74 . The outer shell 62 thus formed includes a vacuum volume or a vacuum cavity, within which is disposed a superconducting magnet assembly. Such a magnet assembly may be utilized for an open MR system, such as an open MRI or open magnetic resonance spectroscopy systems.
[0032] FIG. 6 is a diagrammatic view of a superconducting magnet that may be disposed horizontally within an outer shell of a magnet assembly in an MR system. As shown, the composite bobbin 42 of the superconducting magnet assembly 26 includes recesses 44 . Although only two recesses 44 are shown, the composite bobbin 42 may include more recesses. The recesses 44 are wound with a superconducting coil 46 . The superconducting coil 46 in the two recesses 44 are joined together via jumpers or electrical coupling that runs over the composite bobbin 42 . Leads 54 of the superconducting coil 46 are conducted to electrical coupling with a magnet operation control circuitry. A cryogen coil 76 is arranged over the composite bobbin 42 in an anti-vapor-locking configuration, as shown. For example, in a horizontally-oriented superconducting magnet structure 26 , the cryogen coil 76 may be disposed in a commonly known refrigerator cooling coil configuration. This refrigerator cooling coil configuration in the horizontally-oriented superconducting magnet structure 26 prevents vapor-locking of the cryogen, as will be appreciated by those skilled in the art. The cryogen feed mechanism feeds liquid helium, or other cryogen known in the art, into the cryogen coil 76 in a direction shown generally by reference numeral 78 . The cryogen flows down into the bottom 80 of the cryogen coil 76 . As the cryogen cools the superconducting magnet 26 , the cryogen vaporizes and passes through the serpentine cryogen coil 76 , without any cryogen vapor being locked in the cryogen coil 76 . The vaporized cryogen escapes into the cryogen feed mechanism in the direction generally shown by reference numeral 82 .
[0033] The composite bobbin 42 , made of thermally conductive material, as described previously helps in conducting heat away from the superconducting coils thus maintaining superconducting operation. The generated heat is conducted away towards the cryogenic coil 48 . The thermally conductive composite bobbin 42 therefore reduces the thermal gradient between the superconducting coil 46 and the cryogenic coil 48 .
[0034] FIG. 7 is a diagrammatic view of a superconducting magnet that may be disposed vertically within an outer shell of a magnet assembly in an MR system. FIG. 7 shows the composite bobbin 42 of the superconducting magnet assembly 26 including the recesses 44 . As shown, cryogen coil 84 is arranged over the composite bobbin 42 in an anti-vapor-locking configuration. In this vertically-oriented superconducting magnet structure 26 , the cryogen coil 84 is disposed in a helical configuration. Again, this helical configuration in the vertically-oriented superconducting magnet structure 26 prevents vapor-locking of the cryogen. The cryogen feed mechanism feeds cryogen into the cryogen coil 84 in a direction shown generally by reference numeral 86 . The cryogen cools the superconducting magnet 26 and vaporizes through the spiral cryogen coil 84 . The vaporized cryogen escapes into the cryogen feed mechanism in the direction generally shown by reference numeral 88 .
[0035] The forgoing structures may be used in a range of systems and applications, such as for magnetic resonance imaging. Referring generally to FIG. 8 , a magnetic resonance (MR) system 90 , such as for a magnetic resonance imaging or magnetic resonance spectroscopy application, is shown in which the forgoing structures are incorporated. The MR system 90 shows a closed MR system, having a bore 92 for receiving a subject 94 . Subject 94 may lie over a patient table 96 that may be introduced into the bore 92 . A magnet assembly 10 including a superconducting magnet assembly 26 made via the techniques discussed above may be utilized to generate the magnetic field for the MR system 90 . The superconducting operation may be controlled via an imaging control circuitry 98 .
[0036] Referring now to FIG. 9 , an open MR system 100 is shown. The magnetic field for the open MR system 100 may be generated by a magnet assembly 10 . The magnet assembly 10 may include an outer shell 62 , constructed in accordance with the teachings of FIG. 5 . Within the outer shell 62 , a superconducting magnet assembly 26 may be disposed, which may have a thick disc shape without a bore. Again, the superconducting operation may be controlled via an imaging control circuitry 98 .
[0037] Although the embodiments illustrated and described hereinabove represent only a limited number of embodiments, it should be readily understood that the invention is not limited to such disclosed embodiments. Rather, the invention can be modified to incorporate any number of variations, alterations, substitutions or equivalent arrangements not heretofore described, but which are commensurate with the spirit and scope of the invention. For example, the magnet assembly 10 including the outer shell 12 that encloses the superconducting magnet assembly 26 , may be constructed in a conventional patient bore configuration, an open MRI configuration, a long-U configuration, among others.
[0038] Additionally, while various embodiments of the invention have been described, it is to be understood that aspects of the invention may include only some of the described embodiments. Accordingly, the invention is not to be seen as limited by the foregoing description, but is only limited by the scope of the appended claims. | A composite sealed vessel is provided. The vessel includes a non-metallic, generally cylindrical inner containment piece, a non-metallic, generally cylindrical outer containment piece disposed around the inner containment piece. A pair of non-metallic flanges are disposed at ends of the inner and outer containment pieces to form a closed structure defining a cavity therein. The vessel also includes a metallic external lining disposed over the closed structure to form a leak-tight pressure boundary. | 8 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims the benefit of the filing date of Provisional Patent Application Serial No. 60/312,121, filed on Aug. 14, 2001, and entitled “Method of Coaxially Aligning the Signal Center Axis with the Hub Center Axis of an Optical Disc”, and Provisional Patent Application Serial No. 60/314,473, filed on Aug. 23, 2001, and entitled “Dual Signal Layer and Thin Substrate Optical Disc and Related Methods.”
FIELD OF THE INVENTION
[0002] This invention relates generally to optical discs, and in particular, a method of coaxially aligning the signal center axis of the optical disc with the hub center axis of the optical disc, and the resulting optical disc.
BACKGROUND OF THE INVENTION
[0003] An optical disc typically consists of a signal layer formed on a disc-shaped substrate having a central opening. The signal layer spirals around the disc-shaped substrate about a center longitudinal axis. In addition, the optical disc typically includes a generally cylindrical and metallic hub situated within the central opening of the disc-shaped substrate. The hub also has a corresponding center longitudinal axis. When the optical disc is properly inserted into a reader, the hub is coaxially mounted to the spindle motor of the reader (i.e. the hub center is substantially concentric with the center of rotation of the motor). In order for the optical disc reader to read the signal layer properly, the signal center axis should be substantially coaxial with the center of rotation of the spindle motor. Therefore, it follows that the signal center axis should be substantially coaxial with the hub center axis.
[0004] [0004]FIG. 1 illustrates a cross-sectional view of a prior art double-sided optical disc 100 . The optical disc 100 consists of a disc-shaped substrate 102 having a central opening 104 . An upper signal layer 106 a is formed on the upper surface of the substrate 102 and a lower signal layer 106 b is formed on the lower surface of the substrate 102 . The upper signal layer 106 a has an associated signal center longitudinal axis C SA and the lower signal layer 106 b has an associated signal center longitudinal axis C SB . The optical disc 100 further consists of an upper hub 108 a and a lower hub 108 b . The upper and lower hubs 108 a - b consists of respective cylindrical portions 110 a - b that extend coaxially within the central opening 104 of the substrate 102 and respective lip portions 112 a - b that mount on the upper and lower surfaces of the substrate 102 , respectively. The upper hub 108 a has an associated center longitudinal axis C HA and the lower hub 108 b has an associated center longitudinal axis C HB .
[0005] As previously discussed, in order for the optical disc reader to properly read the signal layers 106 a - b of the optical disc 100 , the signal center longitudinal axes C SA and C SB should be substantially coaxial with the hub center longitudinal axes C HA and C HB , respectively. However, in the prior art optical disc 100 , the signal center longitudinal axes C SA and C SB do not necessarily coincide with the center longitudinal axis of the disc-shaped substrate 102 or with each other. In addition, the hub center longitudinal axes C HA and C HB do not necessarily coincide with the center longitudinal axes of the disc-shaped substrate 102 or with each other. Thus, in order to align the signal center longitudinal axes C SA and C SB respectively to the hub center longitudinal axes C HA and C HB , lots of trial and error and/or specialized equipment are required. This is typically difficult to accomplish, time-consuming, expensive, and complicates the manufacturing of optical discs.
[0006] Thus, there is a need for an improved method of aligning the signal center longitudinal axis with the hub center longitudinal axis of the optical disc.
SUMMARY OF THE INVENTION
[0007] An optical disc according to an embodiment of the invention includes a first substrate having a first central opening, a first signal layer formed on one of the surfaces of the first substrate, a second substrate having a second central opening, a second signal layer formed on one of the surfaces of the second substrate, and a hub having a central longitudinal axis. The first substrate and the first signal layer are designed such that a first central longitudinal axis of the first opening substantially coaxially aligns with a first central longitudinal axis of the first signal layer, and the second substrate and the second signal layer are designed such that a second central longitudinal axis of the second opening substantially coaxially aligns with a second central longitudinal axis of the second signal layer. The first substrate, the second substrate and the hub are bonded together with the result of substantially coaxially alignment of the central longitudinal axis of the first signal layer, the second signal layer and the hub.
[0008] A thickness of the first substrate and a thickness of the second substrate can be substantially same.
[0009] A thickness of the first substrate can also be less than a thickness of the second substrate. For example, the thickness of the first substrate is between 0.05 mm and 0.2 mm, and the thickness of the second substrate is greater than 0.3 mm.
[0010] The hub may comprise a magnetic material or a magnetic sensitive material.
[0011] The signal layer may comprise a recordable material such as a phase change material.
BRIEF DESCRIPTION OF THE DRAWINGS
[0012] FIGS. 1 illustrates a cross-sectional view of a prior art optical disc;
[0013] [0013]FIG. 2A illustrates a cross-sectional view of an exploded exemplary optical disc in accordance with embodiment 1 of the invention;
[0014] [0014]FIG. 2B illustrates a cross-sectional view of an assembled exemplary optical disc in accordance with embodiment 1 of the invention;
[0015] [0015]FIG. 3A illustrates a cross-sectional view of an exploded exemplary optical disc in accordance with embodiment 2 of the invention;
[0016] [0016]FIG. 3B illustrates a cross-sectional view of an assembled exemplary optical disc in accordance with embodiment 2 of the invention.
[0017] [0017]FIG. 4A illustrates a cross-sectional view of an exploded exemplary optical disc in accordance with embodiment 3 of the invention;
[0018] [0018]FIG. 4B illustrates a cross-sectional view of an assembled exemplary optical disc in accordance with embodiment 3 of the invention;
[0019] [0019]FIG. 5A illustrates a cross-sectional view of an exploded exemplary optical disc in accordance with embodiment 4 of the invention; and
[0020] [0020]FIG. 5B illustrates a cross-sectional view of an assembled exemplary optical disc in accordance with embodiment 4 of the invention.
DETAILED DESCRIPTION OF THE INVENTION
[0021] (Embodiment 1)
[0022] [0022]FIG. 2A illustrates a cross-sectional view of an exploded exemplary optical disc 200 in accordance with embodiment 1 of the invention. The optical disc 200 comprises an upper disc-shaped substrate 202 a with an upper central opening 204 a . The upper substrate 202 a comprises an upper annular protrusion 206 a extending above the top surface of the upper substrate 202 a , and defining the boundary of the upper central opening 204 a . In addition, the upper substrate 202 a comprises an annular notch 208 a located at the bottom surface and coaxial with the central opening 204 a of the upper substrate 202 a . The upper central opening 204 a has a central longitudinal axis C OA .
[0023] The optical disc 200 comprises a lower disc-shaped substrate 202 b with a lower central opening 204 b . The lower substrate 202 b comprises a lower annular protrusion 206 b extending below the lower surface of the lower substrate 202 b , and defining the boundary of the lower central opening 204 b . In addition, the lower substrate 204 b comprises an annular notch 208 b located at the top surface and coaxial with the central opening 204 b of the lower substrate 202 b . The lower central opening 202 b has a central longitudinal axis C OB .
[0024] The optical disc 200 of the invention further comprises an upper signal layer 210 a formed on the upper surface of the upper substrate 202 a , and a lower signal layer 210 b formed on the lower surface of the lower substrate 202 b . The upper signal layer 210 a has a central longitudinal axis C SA , and the lower signal layer 210 b has a central longitudinal axis C SB . Additionally, the optical disc 200 comprises a cylindrical hub 212 having an annular protrusion 214 extending outwardly from the outer cylindrical wall of the hub 212 . The annular protrusion 214 is centrally located along the cylindrical wall of the hub 212 . The cylindrical hub 212 has a central longitudinal axis C H .
[0025] [0025]FIG. 2B illustrates a cross-sectional view of the assembled exemplary optical disc 200 in accordance with embodiment 1 of the invention. Assembled, the lower surface of the upper substrate 202 a is attached to the upper surface of the lower substrate 202 b using an adhesive 218 . The attachment of the upper substrate 202 a to the lower substrate 202 b forms an annular groove 216 by the mating of the upper annular notch 208 a to the lower annular notch 208 b . The annular protrusion 214 of the hub 212 registers within the annular groove 216 . The length of the annular protrusion 214 of the hub 212 is smaller than the depth of the annular groove 216 so that the outer cylindrical wall of the hub 212 are flushed with the walls of the central openings 204 a - b.
[0026] The following explains the method of aligning the central longitudinal axes C SA and C SB of the upper and lower signal layers 210 a - b to the central longitudinal axis C H of the hub 212 in accordance with the invention. The upper substrate 202 a and the upper signal layer 210 a are designed such that the central longitudinal axis C SA of the upper signal layer 210 a coaxially aligns with the central longitudinal axis C OA of the upper central opening 204 a of the upper substrate 202 a . Also, the lower substrate 202 b and the lower signal layer 210 b are designed such that the central longitudinal axis C SB of the lower signal layer 210 b coaxially aligns with the central longitudinal axis C OB of the lower central opening 204 b of the lower substrate 202 b.
[0027] The hub 212 , having its outer cylindrical wall flushed with the walls of the upper and lower central openings 204 a - b , has a central longitudinal axis C H that is coaxially aligned with the central longitudinal axes C OA and C OB of the upper and lower central openings 204 a - b . Since the central longitudinal axes C SA and C SB of the upper and lower signal layers 210 a - b coaxially align with the central longitudinal axes C OA and C OB of the upper and lower central openings 204 a - b , it follows that the central longitudinal axes C SA and C SB of the upper and lower signal layers 210 a - b are coaxially aligned with the central longitudinal axis C H of the hub 212 . This condition allows for proper reading of the signal layers 210 a - b by an optical disc reader.
[0028] (Embodiment 2)
[0029] FIGS. 3 A-B illustrate respective cross-sectional views of an exploded and assembled exemplary optical disc 300 in accordance with embodiment 2 of the invention. The optical disc 300 is the same as the optical disc 200 , except that protective layers 316 a - b cover respectively the upper and lower signal layers 310 a - b.
[0030] (Embodiment 3)
[0031] [0031]FIG. 4A illustrates a cross-sectional view of an exploded exemplary optical disc 400 in accordance with embodiment 3 of the invention. The optical disc 400 comprises an upper disc-shaped substrate 402 a with an upper central opening 404 a . In the exemplary embodiment, the thickness of the upper substrate 402 a is greater than approximately 0.3 mm. The upper central opening 404 a has a central longitudinal axis C OA . The upper substrate 402 a further comprises an upper signal layer 410 a formed on the lower surface of the upper substrate 402 a . The upper signal layer 410 a spirals around a central longitudinal axis C SA .
[0032] The optical disc 400 further comprises a lower disc-shaped substrate 402 b with a lower central opening 404 b . In the exemplary embodiment, the thickness of the lower substrate 402 b is approximately 0.05 to 0.2 mm. The lower central opening 402 b has a central longitudinal axis C OB . The lower substrate 402 b further comprises a lower signal layer 410 b formed on the upper surface of the lower substrate 402 b . The lower signal layer 410 b spirals around a central longitudinal axis C SB .
[0033] Additionally, the optical disc 400 comprises a hub 412 having an upper cylindrical portion 412 a and a lower cylindrical portion 412 b . In the exemplary embodiment, the diameter of the outer walls of the lower cylindrical portion 412 b is greater than the diameter of the outer walls of the upper cylindrical portion 412 a . The hub further includes a thru-opening 412 c that extends longitudinally and coaxially through the upper and lower cylindrical portions 412 a and 412 b of the hub 412 . The central longitudinal axis of the hub 412 can be represented as C H .
[0034] [0034]FIG. 4B illustrates a cross-sectional view of the assembled exemplary optical disc 400 in accordance with the invention. Assembled, the lower surface of the upper substrate 402 a is attached to the upper surface of the lower substrate 402 b using an adhesive 414 . Also assembled, the upper cylindrical portion 412 a of the hub 412 extends coaxially within the opening 404 a of the upper substrate 402 a . Additionally, the lower cylindrical portion 412 b of the hub 412 extends coaxially within and below the opening 404 b of the lower substrate 402 b.
[0035] The following explains the method of aligning the central longitudinal axes C SA and C SB of the upper and lower signal layers 410 a - b to the central longitudinal axis C H of the hub 412 in accordance with the invention. The upper substrate 402 a and the upper signal layer 410 a are designed such that the central longitudinal axis C SA of the upper signal layer 410 a substantially coaxially aligns with the central longitudinal axis C OA of the upper central opening 404 a of the upper substrate 402 a . Also, the lower substrate 402 b and the lower signal layer 410 b are designed such that the central longitudinal axis C SB of the lower signal layer 410 b substantially coaxially aligns with the central longitudinal axis C OB of the lower central opening 404 b of the lower substrate 402 b . These substantially coaxial relations C SA =C OA and C SB =C OB can be easily obtained by regular molding of substrates, similar to current CD, DVD, and MD molding processes.
[0036] The hub 412 , having its upper and lower cylindrical portions 412 a - b flushed with the walls of the upper and lower central openings 404 a - b , has a central longitudinal axis C H that is substantially coaxially aligned with the central longitudinal axes C OA and C OB of the upper and lower central openings 404 a - b . Since the central longitudinal axes C SA and C SB of the upper and lower signal layers 410 a - b substantially coaxially align with the central longitudinal axes C OA and C OB of the upper and lower central openings 404 a - b , it follows that the central longitudinal axes C SA and C SB of the upper and lower signal layers 410 a - b are substantially coaxially aligned with the central longitudinal axis C H of the hub 412 . This condition allows for proper reading of the signal layers 410 a - b by an optical disc reader.
[0037] (Embodiment 4)
[0038] [0038]FIG. 5A illustrates a cross-sectional view of an exploded exemplary optical disc 500 in accordance with embodiment 4 of the invention. The optical disc 500 comprises an upper disc-shaped substrate 502 a with an upper central opening 502 a having an upper portion 504 a - 1 and a lower portion 504 a - 2 . In the exemplary embodiment, the diameter of the upper portion 504 a - 1 is less than the diameter of the lower portion 504 a - 2 of the upper central opening 504 a . The upper central opening 502 a has a central longitudinal axis C OA . Also in the exemplary embodiment, the thickness of the upper substrate 502 a is greater than approximately 0.3 mm. The upper substrate 502 a further comprises an upper signal layer 510 a formed on the lower surface of the upper substrate 502 a . The upper signal layer 510 a spirals around a central longitudinal axis C SA .
[0039] The optical disc 500 further comprises a lower disc-shaped substrate 502 b with a lower central opening 504 b . In the exemplary embodiment, the thickness of the lower substrate 502 b is approximately 0.05 to 0.2 mm. The lower central opening 502 b has a central longitudinal axis C OB . The lower substrate 502 b includes an annular protrusion 508 that extends below the lower surface of the lower substrate 502 b and defines a lower portion of the central opening 504 b . In addition, the lower substrate 502 b further comprises a lower signal layer 510 b formed on the upper surface of the lower substrate 502 b . The lower signal layer 510 b spirals around a central longitudinal axis C SB .
[0040] Additionally, the optical disc 500 comprises a hub 512 having an upper cylindrical portion 512 a , a lower cylindrical portion 512 b , and a middle cylindrical portion 512 c . In the exemplary embodiment, the diameter of the outer walls of the middle cylindrical portion 512 c is greater than the diameters of the outer walls of the lower and upper cylindrical portion 512 a - b , which are substantially the same. The hub further includes a thru-opening 512 d that extends longitudinally and coaxially through the upper, lower, and middle cylindrical portions 512 a - c of the hub 512 . The central longitudinal axis of the hub 512 can be represented as C H .
[0041] [0041]FIG. 5B illustrates a cross-sectional view of the assembled exemplary optical disc 300 in accordance with embodiment 4 of the invention. Assembled, the lower surface of the upper substrate 502 a is attached to the upper surface of the lower substrate 502 b using an adhesive 514 . Also assembled, the upper cylindrical portion 512 a of the hub 512 extends coaxially within the upper portion 504 a - 1 of the upper central opening 504 a of the upper substrate 502 a . The middle cylindrical portion 512 c of the hub 512 extends coaxially within the lower portion 504 a - 2 of the upper central opening 504 a of the upper substrate 502 a . Additionally, the lower cylindrical portion 512 b of the hub 512 extends coaxially within the opening 504 b of the lower substrate 502 b.
[0042] The following explains the method of aligning the central longitudinal axes C SA and C SB of the upper and lower signal layers 510 a - b to the central longitudinal axis C H Of the hub 512 in accordance with the invention. The upper substrate 502 a and the upper signal layer 510 a are designed such that the central longitudinal axis C SA of the upper signal layer 510 a substantially coaxially aligns with the central longitudinal axis C OA of the upper central opening 504 a of the upper substrate 502 a . Also, the lower substrate 502 b and the lower signal layer 510 b are designed such that the central longitudinal axis C SB of the lower signal layer 510 b substantially coaxially aligns with the central longitudinal axis C OB of the lower central opening 504 b of the lower substrate 502 b . These substantially coaxial relations C SA =C OA and C SB =C OB can be easily obtained by regular molding of substrates, similar to current CD, DVD, and MD molding processes.
[0043] The hub 512 , having its upper and middle cylindrical portions 512 a and 512 c flushed with the walls of the upper and lower portions 504 a - 1 - 2 of the upper central openings 504 a , has a central longitudinal axis C H that is coaxially aligned with the central longitudinal axis C OA of the upper central opening 504 a . Also, the hub 512 , having its lower cylindrical portion 512 b flushed with the wall of the lower central opening 504 b , has its central longitudinal axis C H coaxially aligned with the central longitudinal axis C OB of the lower central opening 504 b . Since the central longitudinal axes C SA and C SB of the upper and lower signal layers 510 a - b coaxially align with the central longitudinal axes C OA and C OB of the upper and lower central openings 504 a - b , it follows that the central longitudinal axes C SA and C SB of the upper and lower signal layers 510 a - b are coaxially aligned with the central longitudinal axis C H of the hub 512 . This condition allows for proper reading of the signal layers 510 a - b by an optical disc reader.
[0044] In the exemplary optical discs 200 , 300 , 400 and 500 , the substrates may be formed of a polycarbonate, the hub is formed of a magnetically-sensitive metal, the adhesive is formed of a bonding resin, such as a ultraviolet curing resin, the signal layers are formed of a reflective layer, such as a phase change material (Te—Ge—Sb), and the protective layer is formed of a ultraviolet curing resin with lower viscosity. The optical disc 200 , 300 , 400 or 500 can be a compact disc (CD), a digital versatile disc (DVD), a micro disc (MD), a Data Play disc, or other format. These discs can be formed by a molding process or by a stamping process. If a molding process is used, the discs can be removed from the molding fixture using an air ejection process.
[0045] In the foregoing specification, the invention has been described with reference to specific embodiments thereof. It will, however, be evident that various modifications and changes may be made thereto without departing from the broader spirit and scope of the invention. The specification and drawings are, accordingly, to be regarded in an illustrative rather than a restrictive sense. | An optical disc includes a first substrate having a first central opening, a first signal layer formed on one of the surfaces of the first substrate, a second substrate having a second central opening, a second signal layer formed on one of the surfaces of the second substrate, and a hub having a central longitudinal axis. The first substrate and the first signal layer are designed such that a first central longitudinal axis of the first opening substantially coaxially aligns with a first central longitudinal axis of the first signal layer, and the second substrate and the second signal layer are designed such that a second central longitudinal axis of the second opening substantially coaxially aligns with a second central longitudinal axis of the second signal layer. The first substrate, the second substrate and the hub are bonded together with the result of substantially coaxially alignment of the central longitudinal axis of the first signal layer, the second signal layer and the hub. | 6 |
BACKGROUND OF THE INVENTION
This invention relates to polyvinyl butyral resin and more particularly to a method of producing polyvinyl butyral resin from polyvinyl alcohol.
Plasticized polyvinyl butyral sheet is very well known as an interlayer for use with glass or rigid plastic panels in laminated safety glazing assemblies. The polyvinyl butyral resin is more particularly partial polyvinyl butyral insofar as containing about 15 to about 30 percent by weight residual hydroxyl groups which promote adherence of the sheet to the glass or plastic. Such polyvinyl butyral or partial polyvinyl butyral, (interchangeably referred to as PVB), is conventionally prepared by partially acetalizing polyvinyl alcohol (PVOH) with butyraldehyde. The PVB is then conventionally mixed with plasticizer and melt processed into sheeting which is usually collected and stored in roll form before use. In use, sections for individual glazing units are cut from the roll, placed between or adjacent one or more laminating panels and the sandwich pressed together in an autoclave at elevated temperature and pressure to form the laminate.
Plasticized PVB sheet used in this way inherently tends to stick to itself (sometimes called "blocking") at ambient temperatures typically encountered during storage before laminating. Expensive precautions have been taken to prevent this. For example, the sheet has been transported and stored at low refrigeration temperatures, or interleaved with polyethylene film or dusted between facing layers with sodium bicarbonate. It has been and continues to be very desirable to alleviate this blocking problem associated with plasticized PVB sheet.
Another problem occurs during laminating when incomplete contact exists between the PVB sheet and the contiguous laminating panel. This is caused by thickness tolerance variations in the sheet and laminating panel and results in visually apparent, local, unlaminated patches appearing as bubbles. In the past, when these patches appeared on laminating lines the problem was overcome by extending the autoclave cycle to heat the sheet to a higher temperature to promote greater polymer flow. But this undesirably results in increased energy costs and imposes a capacity-affecting limitation on laminating lines. Tailoring the sheet polymer modulus to promote slight additional flow into an uneven area of the gap between the sheet and opposing panel could alleviate the problem. But this works at cross purposes with minimizing sticking of the sheet to itself before laminating. In other words, reducing modulus to promote flow during laminating will undesirably increase stickiness at ambient temperature. On the other hand, increasing ambient temperature modulus to stiffen the sheet enough to resist sticking will decrease flow during laminating. Yet optimum flow during laminating is increasingly important in vehicle glazing applications as the amount of glass per vehicle is increased.
It would be very desirable to simultaneously favorably influence each of these problem areas associated with use of plasticized PVB sheet in laminated safety glazings and avoid performance trade-offs which have occurred in reducing one problem at the expense of the other. To the best of our knowledge, however, such corrections have not been provided in the prior art.
SUMMARY OF THE INVENTION
Now improvements have been made to increase the ambient temperature resistance of PVB sheet to blocking while simultaneously improving its flow during lamination.
Accordingly, a principal object of this invention is to chemically modify PVB resin so that when used as a sheet for safety glazings the usual stack or roll sticking and laminate flow problems are reduced or eliminated.
A specific object is to provide a process for chemically synthesizing PVB resin which is modified to alter the PVB to favorably influence sticking and laminate flow.
Another object is to achieve the foregoing objects without significantly departing from conventional ways of synthesizing PVB resin, forming plasticized PVB sheet and laminating such sheet with other panels to form a safety glazing.
These and other objects are accomplished by providing a new species of PVB resin which contains ionomeric groups capable of providing thermally reversible ionic crosslinks ("ionomeric PVB" abbreviated as "IPVB"). More specifically, at low ambient temperatures (ca 40°-60° C.) where sticking problems occur, such temperature-dependent ionic crosslinks are inherently established to promote block resistance whereas at elevated laminating temperatures where flow is important, such linkages are inherently severed to promote flow into uneven portions of the gap between the sheet and opposing laminating panel(s).
The IPVB resin contains a modification-promoting amount of ionomeric groups chemically combined therein, preferably to oxygen atoms of adjacent precursor vinyl alcohol groups. Such ionomeric groups are preferably present at up to about 15 and most preferably about 2 to about 5 mole percent. The ionomeric groups are bound into the PVB preferably through the reaction between an aldehyde group and two hydroxyl groups. A particularly preferred ionomeric group is the metal sulfonate salt of an aldehyde. Polyvinyl alcohol containing chemically bound ionic acid groups is the precursor for the ionomeric PVB resin.
In a more specific aspect there is provided a method of producing inomeric polyvinyl butyral by steps comprising:
(a) condensing polyvinyl alcohol with an aldehyde containing an acid group in the presence of a catalyst;
(b) acetalizing the reaction product of step (a) in the presence of a catalyst to form polyvinyl butyral; and
(c) neutralizing the reaction product of step (b) to form the ionomeric polyvinyl butyral.
DETAILED DESCRIPTION OF THE INVENTION
IPVB resin is an ionized copolymer comprising a major component of a non-ionic backbone of partial PVB containing 65-95 weight percent vinyl butyral units, 15 to 30 weight percent hydroxyl groups calculated as vinyl alcohol and 0 to 5 percent vinyl ester units (calculated as vinyl acetate) and a minor component of an ionizable or ionic comonomer. The latter minor component distinguishes IPVB from partial PVB traditionally used in sheeting for glazing applications and is provided by chemically modifying the polyvinyl alcohol in conjunction with acetalization with butyraldehyde to form the non-ionic partial PVB resin backbone. PVOH modification is done through attachment of ionic acidic groups to a pair of hydroxyl groups of the PVOH to form a modified PVOH precursor to the IPVB. This modification is done by the chemical condensation reaction of PVOH and, preferably, an ionic aldehyde. This is illustrated by the following reaction where the acidic groups are ionic sulfonated benzal groups obtained by reacting PVOH with the sodium salt of 2-formyl benzene sulfonic acid (BSNA) having the following structural formula: ##STR1## The PVOH reaction in the presence of HNO 3 catalyst is illustrated as follows: ##STR2##
Usable PVOH (either a single grade or two or more grades blended together) are commercially available, for example from Air Products and Chemicals, Inc. or E. I. du Pont de Nemours & Co., Inc. They are characterized by degree of polymerization (DP) which ranges from about 350 to 2500 to provide PVOH molecular weight from 15,000 to 110,000. As an optional feature, low molecular weight PVOH having a DP of 350 to 800 and a molecular weight of about 15,000 to about 35,000 can be used when certain ionomeric components (described hereinafter) are used and the PVOH-ionomeric and acetalization reactions are conducted at low temperature below 20° C. Such low molecular weight PVOH has traditionally not been sufficiently reactive with butyraldehyde to make PVB due to the physical nature of the material which causes it to agglomerate. Its use is desirable since in furtherance of the objects of this invention the correspondingly low molecular weight PVB formed will be "softer" and flow better at laminating temperatures while, due to the presence of ionomeric groups, being stiffer and more block resistant at ambient temperatures in comparison with results using all medium or high molecular weight PVOH (and resulting high molecular weight PVB). Medium to high molecular weight PVOH's have a DP of about 810 to 15,000 and a molecular weight of about 35,500 to about 110,000.
The modified PVOH containing the ionic acid groups is acetalized under aqueous or solvent acetalization conditions by reacting the PVOH precursor with butyraldehyde in the presence of an acid catalyst. The acetalized reaction product is then neutralized to form the polymer salt. Neutralization need not be complete in that some unneutralized product in acid form can be present but neutralization has to be sufficient to give the ionic associations in use which are later more completely described. Neutralization is effected by adding metal ions such as Na + , K + , Ca ++ , Ba ++ , Zn ++ , NH 4 + etc. to the reaction medium. Using the precursor shown above, this is illustrated by the following reactions to form one species of IPVB according to the invention: ##STR3## The ionomeric groups of the foregoing IPVB species are present as the sodium salt of sulfonated polyvinyl benzal chemically bound to oxygen atoms of adjacent precursor vinyl alcohol groups formed initially through reaction between a CHO aldehyde group of the BSNA ionomeric constituent and two hydroxyl groups on a PVOH molecule.
In a solvent process acetalization occurs in the presence of acid catalyst and sufficient solvent to dissolve the modified PVB formed and produce a homogeneous solution at the end of acetalization. The modified PVB is separated from solution by precipitation of solid particles with water which are then washed, neutralized and dried. Solvents used are lower aliphatic alcohols, such as ethanol.
In an aqueous process, acetalization occurs by adding butyraldehyde to a water solution of modified PVOH in the presence of an acid catalyst, agitating the mixture to cause the modified PVB to precipitate in finely divided form and continuing agitation until the reaction mixture has proceeded to the desired end point.
Acetalization with butyraldehyde in a solvent or aqueous process is preferably carried out in situ with the PVOH reaction through which the ionic acidic groups had previously been attached to the PVOH molecules. This is achieved by adding butyraldehyde directly to the reaction zone to commence condensation with the modified PVOH after the desired amount of PVOH has reacted with the ionic component. Depending on the chemical nature of the compound selected to provide the ionomeric bonds, it may be possible to carry out the ionomeric reaction with PVOH and the acetalization reactions simultaneously. It is preferred, however, to conduct these reactions sequentially in situ when the reaction rate with PVOH of the butyraldehyde significantly exceeds that of the ionomeric constituent, as is the case when a substituted aldehydic aromatic salt is used to provide the ionomeric groups.
The extent of modification of the starting PVOH and the content of ionomeric groups in the IPVB product can vary widely as a function of the extent of the reaction of the PVOH and the ionic-containing component. Generally, satisfactory results are obtained when the modified PVOH precursor contains up to about 15, preferably up to about 10 and most preferably 2 to 5 mole percent acidic ionic groups and the IPVB resin similarly contains up to about 15, preferably up to about 10 and most preferably 2 to 5 mole percent ionomeric groups obtained from the modified PVOH precursor.
The temperature of the PVOH reaction should be adequate to reactively bind the desired amount of acidic ionic groups to the PVOH and will vary with the ionomeric component chosen. When a substituted aldehydic aromatic salt is used, such as the preferred BSNA, the temperature throughout the PVOH and acetailization reactions should be below 20° C., preferably between 8-15 and most preferably 10°-12° C.
The IPVB resin of the invention contains a modification-promoting amount of chemically combined ionomieric groups. Insofar as the chemical reaction of the ionic component with polyvinyl alcohol to later produce thermally reversible crosslinks in PVB formed from such modified PVOH, the ionic component, must contain: (i) an active group capable of interacting with two hydroxyl groups of a PVOH molecule to chemically bind the ionic component to the PVOH molecule and (ii) an acid group capable in use (i.e. after the modified PVOH precursor is acetalized with butyraldehyde and neutralized) of forming thermally reversible pseudo cross-links with equivalent ionomeric groups on other similarly modified PVOH chains. With this in mind, the chemical structure of the ionic component can vary broadly and is represented by the formula R--XYZ--M where R is the active group referred to above, X and Y are substituents of certain of such active groups, Z is the acid group referred to above and M is a metal cation. More specifically, R equals an aromatic, aliphatic (straight chained, branched or cyclic) or heterocyclic (i) aldehyde (i.e. containing a --CHO group), (ii) acid (i.e. containing a --COOH group), (iii) acid chloride (i.e. containing a --COCl group) or (iv) isocyanate (i.e. containing an --NCO group), provided that when R is aliphatic it has the configuration (CH 2 ) n where n is an integer from 1 to 200; X and Y, which can be the same or different, are substituents on the aromatic and heterocyclic forms of (i), (ii), (iii), and (iv) and are H or C 1 to C 5 alkyl; Z is SO 3 - , COO - , or PO 4 -3 , and M is a cation selected from alkali metals (Group IA in the Periodic Table), alkaline earth metals (Group IIA of the Periodic Table) and transition metals selected from zinc, copper and manganese. Alkali metals are Li, Na, K, Rb, Cs and Fr; alkaline earth metals are Be, Mg, Ca, Sr, Ba, and Ra. The foregoing description of the ionic component is further depicted in the following table:
__________________________________________________________________________ Aliphatic (straight chain/ Aromatic branched or cyclic) Heterocyclic__________________________________________________________________________Aldehyde ##STR4## MZ(CH.sub.2 ) .sub.nCHO n = 1-200 ##STR5##Acid ##STR6## MZ(CH.sub.2 ) .sub.nCOOH ##STR7##Acid Chloride ##STR8## MZ(CH.sub.2 ) .sub. nCOCl ##STR9##Isocyanate ##STR10## MZ(CH.sub.2 ) .sub.nNCO ##STR11##__________________________________________________________________________
Preferred ionic components are those where R is an aromatic aldehyde, X and Y are H, Z is SO 3 - and M is Na + . The most preferred ionic component is the sodium salt of 2-formylbenzene sulfonic acid, i.e. ##STR12## which is commercially available from Aldrich Company or Eastman Kodak Company.
IPVB resin of the invention has use in unblended form (i.e. 100% basis), as a blending concentrate or intermediate in forming sheeting for glazing applications: using high molecular weight PVOH as a starting material (DP 1275 to 1600), it may be possible to shape the resulting IPVB directly into sheeting without blending. It is preferably blended, usually in minor amount (less than 50 wt. %), with unmodified partial PVB. The amount of IPVB blended with PVB is dictated by the level of ionomeric groups in the IPVB and the performance properties desired in sheet formed from the polyblend. Based on economically reasonable reaction rates with the ionomeric component in forming IPVB, the IPVB component should be present at from about 1 to about 45 weight % (based on total PVB) in the polyblend. Above 45 wt. % the blend is usually too stiff in flow whereas the improvement in sheet performance properties is negligible at less than 1 weight %. The preferred level of IPVB in the polyblend (at 2-5 mole % ionomeric content in the IPVB) is about 10 to about 30 wt. % and most preferably about 20 wt. %. Typical viscosities (7.5% in methanol at 20°C.) of "soft" flow polyblends according to the invention (at 10 to 30 wt. % IPVB) are about 100 to 180 cps as contrasted with about 230 cps for conventional unmodified PVB made from high molecular weight PVOH. A particularly preferred polyblend composition at the ratios just referred to comprises a low molecular weight IPVB (i.e. made from PVOH having a molecular weight of from about 15,000 to about 35,000) and an unmodified high molecular weight PVB (i.e. made form PVOH with a molecular weight of 50,000 to 110,000). Such a blend particularly optimizes the enhanced performance properties in the resulting sheet in that the low molecular weight IPVB promotes high temperature flow with reduced blocking while the high molecular weight PVB provides good impact absorption in a laminate containing such a sheet.
Blending IPVB and PVB can be done with conventional dry blending equipment before combination with plasticizer or preferably with the plasticizer and optional other additives in a conventional high intensity mixer. The polyblend containing IPVB must be plasticized with from about 20 to 80 parts plasticizer per 100 parts of resin blend and more commonly between 25 and 45 parts for conventional laminated safety glass use. This latter concentration is generally used when the PVB components of the blend each contain about 15 to about 30 percent vinyl alcohol by weight. In general, plasticizers commonly employed are esters of a polybasic acid and a polyhydric alcohol. Particularly suitable plasticizers are triethylene glycol di-(2-ethylbutyrate), dihexyl adipate, dioctyl adipate, mixtures of heptyl and nonyl adipates, dibutyl sebacate, polymeric plasticizers such as the oil-modified sebacic alkyds, and mixtures of phosphates and adipates such as disclosed in U.S. Pat. No. 3,841,890 and adipates and alkyl benzyl phthalates such as disclosed in U.S. Pat. No. 4,144,217. Other suitable plasticizers are well known or will be obvious to those skilled in the art.
The preferred process for preparing PVB sheet according to the invention involves mixing the polyblend with plasticizer as noted above and melt processing the plasticized polyblend according to known conventional prior art techniques to form the sheet. Systems for forming such sheet typically involve extrusion by forcing polymer melt through a sheeting die having temperature-controlled die lips or by using a die roll system where molten polymer issuing from the die is cast onto a specially prepared surface of a roll closely adjacent to the die exit which imparts the desired surface characteristics to one side of the molten polymer. Thus, a roll having a surface with minute peaks and valleys forms a sheet from polymer cast thereon with a rough surface generally conforming to the valleys and peaks of the surface. Further details of construction of a die roll system are disclosed in U.S. Pat. No. 4,035,549, col. 3, line 46 through col. 4 line 4, the content of which is incorporated herein by reference.
Alternative conventional techniques known to those skilled in the art may be employed in association with an extrusion process to produce a rough surface on either or both sides of the extruding sheet. These involve the specification and control of one or more of the following: polymer molecular weight distribution, water content of the melt, melt and die exit temperature, die exit geometry etc. Systems describing such techniques are disclosed in U.S. Pat. Nos. 2,904,844; 2,909,810; 3,994,654; 4,575,540 and published European Application No. 0185,863.
In addition to plasticizers, the PVB sheet may contain other additives such as dyes, ultra violet light stabilizers, adhesion control salts, anti-oxidants and the like. The sheet may also be provided with an integral, gradient color band during extrusion by known systems as typically disclosed in U.S. Pat. No. 4,316,868. The sheet of the invention preferably compromises a single layer but could be provided as a multi-layer structure obtained, for example, by coextruding an IPVB layer with or coating an IPVB layer on a conventional PVB sheet of the same or different gage thickness. For example, a layer of IPVB could be compression molded onto a conventional PVB sheet or IPVB resin could be dissolved in a solvent, dip or roll-coated onto a conventional sheet followed by solvent evaporation, or an IPVB layer could be fused to a conventional sheet during laminating with other panels forming the safety glazing at elevated temperature and pressure. Alternatively, the coextruded, coated or fused layer could be formed of a polyblend as previously described.
The plasticized PVB sheet containing residual hydroxyl groups has a block-reducing, flow-promoting amount of ionomeric groups chemically bound to oxygen atoms of adjacent precursor vinyl alcohol groups incorporated into the formulation from which it is made. These ionomeric groups provide thermally reversible pseudo cross-links with equivalent ionomeric groups on other similarly modified PVOH chains of the partial PVB of the sheet. More specifically, subsequent to acetalization with butyraldehyde, and after neutralization with Na0H one species of IPVB of the invention can be schematically depicted as follows: ##STR13##
Regarding the mechanism of formation of the pseudo crosslinks, it is postulated that even though, as depicted above, a cation and anion exist on each ionomeric group, there is still an affinity of the cation and anion of any particular group for competing cation and anion groups on closely adjacent ionomeric groups. This can be schematically depicted as follows where, for simplification, only the ionomeric groups of the IPVB molecule are shown: ##STR14## It is felt that this affinity results in clusters or aggregates of ionomeric groups which form the thermally reversible bonds. More specifically, in the absence of sufficient heat energy to overcome the attraction between adjacent ionomeric groups, the bonds exist to provide the reduced ambient temperature blocking property to the sheet of which they are a part. At higher laminating temperatures, however, when the sheet is being conformed to the space between closely adjacent layers of glass, (or equivalent) the bonds rupture resulting in increased flow than if (theoretically) they existed at such high temperatures to provide stiffer flow. PVB sheet of the invention exhibiting (i) improved block resistance has a storage modulus at 40° C. of greater than 6×10 6 dynes/cm 2 and (ii) increased flow at laminating temperatures as represented by a storage modulus at 150° C. of less than 5×10 5 dynes/cm 2 .
The following tests were conducted on specimens prepared according to specific examples presented hereinafter.
1. Near Infrared Spectroscopy (NIR) to measure residual PVOH groups in the IPVB.
2. Nuclear Magnetic Resonance Spectroscopy (NMR) and Infrared Spectroscopy (IR) to confirm the presence of ionomeric groups.
3. Differential Scanning Calorimeter (DSC) to measure polymer glass transition temperature (Tg).
4. Storage Modulus using a Rheometrics Dynamic Mechanical Spectrometer. This test measures the amount of energy stored in the polymer as a function of temperature. The values at 40° and 60° C. (hereinafter G'(40) or (60)) provide an indication of stiffness at ambient sheet-handling temperatures and are used to predict the tendency of the material to stick to itself. The value at 150° C. (hereinafter G'(150)) provides an indication of flow behavior of the material at higher autoclave temperatures during lamination with glass layer(s).
5. Haze using a Hunter Haze Meter is a measure of the optical clarity of a standard glass laminate (two glass layers) using a particular plasticized formulation as the interlayer.
6. Inherent Blocking is the average load in pounds required to separate two strips in face-to-face contact of the same sample from themselves. Sample strips are pressed together under 2.5 tons (2.27 t) ram pressure for 15 minutes. Using an Instron peel tester, a T-type peel test was then run on each sample at a crosshead speed of 20 in (50.8 cm) per minute and a chart speed of 5 in (12.7 cm) per minute.
Exemplary of the invention are the following specific examples wherein parts and percentages are by weight unless otherwise indicated.
EXAMPLE 1
Synthesis of Ionomeric Polyvinyl Butyral
(A) Polyvinyl Alcohol Precursor
Polyvinyl alcohol (PVOH) resin having a residual polyvinyl acetate content of less than 2% and a molecular weight of 23,000 was dissolved with agitation in water at 85°-90° C. to form an 8.3% solution. 7794.6 g of this PVOH solution was charged to an agitated fluted reactor and its temperature adjusted to 10°-12° C. To this was added 66.4 g of o-benzaldehyde sulfonic acid sodium salt (BSNA), and 171.7 g of a 35% solution of nitric acid. The mixture was held at 10°-12° C. for two hours. Analysis of a sample of the reaction product showed 1 to 3 mole % of the acid had chemically combined with the PVOH.
(B) Ionomeric Polyvinyl Butyral
At the end of the noted two hours, and while the temperature in the reaction zone was kept at 10+-12° C., 450.6 g of butyraldehyde were added to the modified PVOH mixture which was then allowed to react at 10°-12° C. with agitation for 4.5-5.5 hrs. The reactor contents were washed with water once, neutralized with 50% sodium hydroxide to a pH of 11.5-12.0, held at this pH for 1.5 hours at room temperature and then washed again with water to a final pH of 7.5 to 8.0. The product was then filtered and dried to less than 2% moisture. Analysis of the product gave the following results:
Residual PVOH groups: 18-19%
BSNA groups in the polymer: 1 to 3 mole %
Tg: 75° C.
EXAMPLE 2
Blending Ionomeric and Conventional PVB's
Conventional PVB available from Monsanto as RB Butvar® resin having a residual PVOH content of 18.4% was blended with the ionomeric PVB resin of Example 1 at various weight ratios of ionomeric PVB/conventional PVB (IPVB/RB). The blended resins were mixed with dihexyl adipate (DHA) at 32.7 parts plasticizer per hundred parts of resin blend. The plasticized resin blends were compacted in a press at 148.9° C. into "baby cakes". Analytical results obtained were as follows:
______________________________________ G' × 10.sup.6 G' × 10.sup.5 (60° C.) (150° C.) Inherent Roll dynes/ dynes/ Blocking HazeSample cm.sup.2 cm.sup.2 Avg Load (lbs) %______________________________________RB (control) 4.15 7.12 0.67 1.1410/90 IPVB/RB 4.03 5.05 0.55 0.9320/80 IPVB/RB -- -- 0.37 1.1930/70 IPVB/RB 4.19 3.91 0.32 1.58IPVB (100%) 6.73 3.05 -- --______________________________________
The results show that blends containing IPVB are equivalent to the RB Control PVB in ambient temperature stiffness as measured by 60° C. Storage Modulus with 100% IPVB being the stiffest. On the other hand, the blends and pure IPVB exhibit superior flow at higher temperatures than the control PVB as measured by 150° C. Storage Modulus. Potential decrease in roll blocking of the blends is observed from the average load to separate two strips of the same sample from each other, i.e. less force is required for the blends than the control. Optical clarity of laminates prepared with interlayer from the blends is comparable to that of the control.
EXAMPLE 3
Sheet From Blend Containing Ionomeric PVB
A 25/75 IPVB/RB blend was mixed with 32 phr DHA in a non-fluxing (non-melting) high intensity Diosna mixer and, using a 41/2 in (11.4 cm) diameter 32/1 L/D extruder, was extruded into sheeting 30 mils (0.76 mm) thick and 23 in (58.4 cm) wide. Melt temperature was 390°-400° F. (198.9°-204.4° C.). Extrusion was through a die opening onto the surface of an adjacent rotating die roll of the type previously described provided with internal cooling means to regulate the temperature of a die blade in contact with the polymer melt at about 115.5° C. Melt pressure at the die was 2412-3100 kPa. Sheet issuing from the die roll at about 4.6 m/min was passed into a water cooling bath at 10° C. The die lip of the die opening was formed with a compression angle of about 4 degrees. Each side of the formed sheet had a rough surface, the blade side measuring (Rz) 45×10 -5 in or 114×10 -5 cm and the roll side 64×10 -5 or 162.6×10 -5 cm. Roughness was measured with a profilometer such as Model C59 Perthometer from Mahr Gage Co., New York.
The following Storage Modulus results (dynes/cm 2 ) at various temperatures were obtained on sheet samples prepared as described above from various blends of IPVB/RB.
______________________________________ G' G' G' G' (26° C.) (40° C.) (60° C.) (150° C.)Sample ×10.sup.7 ×10.sup.6 ×10.sup.6 ×10.sup.5______________________________________RB (100%) 3.27 5.73 4.09 5.98IPVB/RB (10/90) 4.37 6.12 3.94 6.05IPVB/RB (20/80) 4.54 6.76 4.06 4.97IPVB/RB (25/75) 5.29 7.72 4.21 4.26IPVB/RB (30/70) 5.42 9.35 3.91 3.83______________________________________
The above results clearly show that blends containing IPVB are stiffer at 26° and 40° C. based on Storage Modulus yet more flowable at 150° C. than the RB control. At 60° C., since the values differ only by about 4% from the control, performance is predicted to be essentially comparable.
EXAMPLE 4
Alternative Ionomeric Constituent
This example shows the use of an acid aldehyde in the synthesis of ionomeric PVB. The aldehyde used was p-carboxybenzaldehyde (CBA) having the following chemical structure: ##STR15## Since CBA is ethanol soluble, the PVOH and acetalization reactions were carried out in ethanol.
11 g CBA was dissolved in 280 ml of ethanol in an agitated 2 liter reactor and 53.9 g of PVOH (Goshenol NH-18) added to form a PVOH slurry in ethanol. A few drops of concentrated sulfuric acid catalyst were added until pH was less than one. The slurry was heated to 75° C. and refluxed for 2 hours; 34.0 g of n-butyraldehyde was then added and allowed to react at 75° C. for four hours. The reactor contents was then neutralized with sodium hydroxide to a pH of 12.5 and dumped into water to cause polymer to precipitate. It was then filtered and dried as in Example 1 and found to have a Tg of 90.7° C. (versus 73° C for conventional control PVB). IR spectroscopy results showed the presence of COOH groups prior to neutralization with caustic and COO - peaks in the resin after neutralization.
CONTROL EXAMPLE 1
This control Example illustrates the importance of low temperature in forming ionomeric PVB using BSNA.
The procedure of Example 1 was repeated except that reaction temperature was kept at 16° C. (preparation of precursor) and in part B (preparation of ionomeric PVB) up until gel break occurred (the first appearance of PVB particles) when the temperature was increased to and held at 85° C. for 4 hours. NMR analysis of the polymer product showed no evidence of chemical substitution of the BSNA. This is believed due to the 85° C. high temperature portion of the reaction cycle.
The preceding description is set forth for purposes of illustration only and is not to be taken in a limited sense. Various modifications and alterations will be readily suggested to persons skilled in the art. It is intended, therefore, that the foregoing be considered as exemplary only and that the scope of the invention be ascertained from the following claims. | A method of producing ionomeric polyvinyl butyral by the steps of (a) condensing polyvinyl alcohol with an aldehyde containing an acid group in the presence of a catalyst; (b) acetalizing the reaction product of step (a) in situ with butyraldehyde to form polyvinyl butyral and (c) neutralizing the reaction product of step (b) to form ionomeric polyvinyl butyral. | 2 |
FIELD OF THE INVENTION
[0001] This invention relates to new 4-amino-2-(2 or 3-amino or substituted amino-ethyl or propyl)-phenol compounds and compositions containing these new compounds, as primary intermediates for oxidative coloring of hair fibers.
BACKGROUND TO THE INVENTION
[0002] Coloration of hair is a procedure practiced from antiquity employing a variety of means. In modern times, the method most extensively to color hair is an oxidative dyeing process utilizing one or more oxidative hair coloring agents in combination with one or more oxidizing agents.
[0003] Most commonly a peroxy oxidizing agent is used in combination with one or more oxidative hair coloring agents, generally small molecules capable of diffusing into hair and comprising one or more primary intermediates and one or more couplers. In this procedure, a peroxide material, such as hydrogen peroxide, is employed to activate the small molecules of primary intermediates so that they react with couplers to form larger sized compounds in the hair shaft to color the hair in a variety of shades and colors.
[0004] A wide variety of primary intermediates and couplers have been employed in such oxidative hair coloring systems and compositions. Among the primary intermediates employed there may be mentioned p-phenylenediamine, p-toluenediamine, p-aminophenol, 4-amino-3-methylphenol, N,N-bis(2-hydroxyethyl)-p- phenylene diamine, 1-(2-hydroxyethyl)-4,5-diaminopyrazole and as couplers there may be mentioned resorcinol, 2-methylresorcinol, 3-aminophenol, 2,4-diaminophenoxyethanol, and 5-amino-2-methylphenol.
[0005] There are numerous additional requirements for oxidation dye compounds that are used to dye human hair besides the color or the desired intensity. Thus, the dye compounds must be unobjectionable in regard to toxicological and dermatological properties and must provide the desired hair color with a good light fastness, fastness to a permanent wave treatment, acid fastness and fastness to rubbing. The color of the hair dyed with the dye compounds in each case must be stable for at least 4 to 6 weeks to light, rubbing and chemical agents. Furthermore, an additional requirement is the production of a broad palette of different color shades using different developer and coupler substances. Many of the desired shades have been produced with dyes based on p-aminophenol. However, as indicated in U.S. Pat. No. 4,997,451, the use of p-aminophenol is being questioned, for possible toxicological reasons. The proposed replacements for p-aminophenol have not proved entirely satisfactory. There is therefore a need for new primary intermediate compounds to meet one or more of the desired properties but not possessing the possible toxicological drawbacks possessed by p-aminophenol.
SUMMARY OF THE INVENTION
[0006] It is therefore an object of this invention to provide new primary intermediate compounds useful in place of p-aminophenol to provide a wide range of different color shades with various combinations of primary intermediates and couplers, but which avoids the drawback of p-aminophenol.
[0007] It has been discovered that the new 4-amino-2-(2 or 3-amino or substituted amino-ethyl or propyl)-phenol compounds are suitable primary intermediates for hair coloring compositions and systems for providing good oxidative coloration of hair and for providing acceptable light fastness, fastness to shampooing, good selectivity, fastness to perspiration and permanent wave treatment, and suitable for providing a wide variety of different color shades with various primary intermediate and coupler compounds.
[0008] The invention provides new 4-amino-2-(2 or 3-amino or substituted amino-ethyl or propyl)-phenol compounds of formula (1):
[0009] wherein R 1 and R 2 are each independently selected from hydrogen atoms, a C 1 to C 5 alkyl or hydroxyalkyl group, or R 1 and R 2 together with the nitrogen atom to which they are attached form a 5 or 6 member cyclic ring optionally containing one or more additional atoms selected from O, N or S atoms, such as a piperazine, piperidine, imidazole, or morpholine, and n is equal to 1 or 2, with the proviso that when n is equal to 2 only one of R 1 and R 2 may be hydrogen.
[0010] These novel primary intermediates are used to provide coloration to hair in which there is good dye uptake by the hair and provides shades or colors which are stable over a relatively long period of time. The novel primary intermediates provide for dyeing of hair to impart color or shades that possess good wash fastness and do not undergo significant changes on exposure to light or shampooing.
DETAILED DESCRIPTION OF THE INVENTION
[0011] The new 4-amino-2-(2 or 3-amino or substituted amino-ethyl or propyl)-phenol compounds of formula (1) of this invention can be prepared according to the following reaction sequence, where R 1 and R 2 are as defined herein before:
[0012] In this synthesis procedure nitration of 2-coumaranone or dihydrocoumarin of formula (2) with nitric acid/sulfuric acid produces a compound of formula (3). Reaction of the compound of formula (3) with a reagent of the formula R 1 R 2 NH provides a compound of formula (4). Reduction of the compound of formula (4) with borane-THF complex produces a compound of formula (5). Catalytic hydrogenation of the compound of formula (5) with Pd/C under hydrogen produces a compound of formula (1).
Synthesis Examples 1 to 11
[0013] Employing 2-coumaranone or dihydrocoumarin and the appropriate reagent of the formula R 1 R 2 NH in this synthesis procedure produces the following compounds:
[0014] 4-amino-2-(2-dimethylamino-ethyl)-phenol;
[0015] 4-amino-2-(3-dimethylamino-propyl)-phenol;
[0016] 4-amino-2-(2-diethylamino-ethyl)-phenol;
[0017] 4-amino-2-(3-diethylamino-propyl)-phenol;
[0018] 4-amino-2-(3-amino-propyl)-phenol;
[0019] 4-amino-2-(2-piperidin-1-ylethyl)-phenol;
[0020] 4-amino-2-(3-piperidin-1-ylpropyl)-phenol;
[0021] 4-amino-2-[2-(pyridin-3-ylamino)ethyl]-phenol;
[0022] 4-amino-2-(2-imidazol-1-ylethyl)-phenol;
[0023] 4-amino-2-(2-morpholin-1-ylethyl)-phenol; and
[0024] 4-amino-2-[2-(2-hydroxyethylamino)-ethyl]-phenol.
[0025] As used herein, the term “hair dyeing composition” (also synonymously referred to herein as the hair dye composition, the hair coloring composition, or the hair dye lotion) refers to the composition containing oxidation dyes, including the novel compounds described herein, prior to admixture with the developer composition. The term “developer composition” (also referred to as the oxidizing agent composition or the peroxide composition) refers to compositions containing an oxidizing agent prior to admixture with the hair dyeing composition. The term “hair dye product” or “hair dye system” (also referred to as the hair dyeing system, hair dyeing product, or hair coloring system) interchangeably refer to the combination of the hair dyeing composition and the developer composition before admixture, and may further include a conditioner product and instructions, such product or system often being provided packaged as a kit. The term “hair dyeing product composition” refers to the composition formed by mixing the hair dyeing composition and the developer composition. “Carrier” (or vehicle or base) refers to the combination of ingredients contained in a composition excluding the active agents (e.g., the oxidation hair dyes of the hair dyeing composition).
[0026] Hair coloring (i.e., hair dyeing) compositions of this invention can contain, in combination with oxidation dye couplers, a novel primary intermediate of this invention as the sole primary intermediate or can also contain other primary intermediates. Thus, one or more suitable primary intermediates may be used in combination with the novel primary intermediates of this invention.
[0027] Suitable known primary intermediates include, for example,
[0028] p-phenylenediamine derivatives such as: benzene-1,4-diamine (commonly known as p-phenylenediamine), 2-methyl-benzene-1,4-diamine, 2-chloro-benzene-1,4-diamine, N-phenyl-benzene-1,4-diamine, N-(2-ethoxyethyl)benzene-1,4-diamine, 2-[(4-amino-phenyl)-(2-hydroxy-ethyl)-amino]-ethanol, (commonly known as N,N-bis(2-hydroxyethyl)-p-phenylenediamine) (2,5-diamino-phenyl)-methanol, 1-(2,5-diamino-phenyl)-ethanol, 2-(2,5-diamino-phenyl)-ethanol, N-(4-aminophenyl)benzene-1,4-diamine, 2,6-dimethyl-benzene-1,4-diamine, 2-isopropyl-benzene-1,4-diamine, 1-[(4-aminophenyl)aminol-propan-2-ol, 2-propyl-benzene-1,4-diamine, 1,3-bis[(4-aminophenyl)(2-hydroxyethyl)amino]propan-2-ol, N 4 , N 4 ,2-trimethylbenzene-1,4-diamine, 2-methoxy-benzene-1,4-diamine, 1-(2,5-diaminophenyl)ethane-1,2-diol, 2,3-dimethyl-benzene-1,4-diamine, N-(4-amino-3-hydroxy-phenyl)-acetamide, 2,6-diethylbenzene-1,4-diamine, 2,5-dimethylbenzene-1,4-diamine, 2-thien-2-ylbenzene-1,4-diamine, 2-thien-3-ylbenzene-1,4-diamine, 2-pyridin-3-ylbenzene-1,4-diamine, 1,1′-biphenyl-2,5-diamine, 2-(methoxymethyl)benzene-1,4-diamine, 2-(aminomethyl)benzene-1,4-diamine, 2-(2,5-diaminophenoxy)ethanol, N-[2-(2,5-diaminophenoxy)ethyl]-acetamide, N,N-dimethylbenzene-1,4-diamine, N,N-diethylbenzene-1,4-diamine, N,N-dipropylbenzene-1,4-diamine, 2-[(4-aminophenyl)(ethyl)amino] ethanol, 2-[(4-amino-3-methyl-phenyl)-(2-hydroxy-ethyl)-amino]-ethanol, N-(2-methoxyethyl)-benzene-1,4-diamine, 3-[(4-aminophenyl)amino]propan-1-ol, 3-[(4-aminophenyl)-amino]propane-1,2-diol, N-{4-[(4-aminophenyl)amino]butyl}benzene-1,4-diamine, and 2-[2-(2-{2-[(2,5-diaminophenyl)-oxy]ethoxy}ethoxy)ethoxy]benzene-1,4-diamine;
[0029] p-aminophenol derivatives such as: 4-amino-phenol (commonly known as p-aminophenol), 4-methylamino-phenol, 4-amino-3-methyl-phenol, 4-amino-2-hydroxymethyl-phenol, 4-amino-2-methyl-phenol, 4-amino-2-[(2-hydroxy-ethylamino)-methyl]-phenol, 4-amino-2-methoxymethyl-phenol, 5-amino-2-hydrc ie-1,2-diol,
[0030] Suitable known couplers include, for example:
[0031] phenols, resorcinol and naphthol derivatives such as: naphthalene-1,7-diol, benzene-1,3-diol, 4-chlorobenzene-1,3-diol, naphthalen-1-ol, 2-methyl-naphthalen-1-ol, naphthalene-1,5-diol, naphthalene-2,7-diol, benzene-1,4-diol, 2-methyl-benzene-1 ,3-diol, 7-amino-4-hydroxy-naphthalene-2-sulfonic acid, 2-isopropyl-5-methylphenol, 1,2,3,4-tetrahydro-naphthalene-1,5-diol, 2-chloro-benzene-1,3-diol, 4-hydroxy-naphthalene-1-sulfonic acid, benzene-1,2,3-triol, naphthalene-2,3-diol, 5-dichloro-2-methylbenzene-1,3-diol, 4,6-dichlorobenzene-1,3-diol, and 2,3-dihydroxy-[1,4]naphthoquinone;
[0032] m-phenylenediamines such as: 2,4-diaminophenol, benzene-1,3-diamine, 2-(2,4-diamino-phenoxy)-ethanol, 2-[(3-amino-phenyl)-(2-hydroxy-ethyl)-amino]-ethanol, 2-mehyl-benzene-1,3-diamine, 2-[[2-(2,4-diamino-phenoxy)-ethyl]-(2-hydroxy-ethyl)-amino]-ethanol, 4-{3-[(2,4-diaminophenyl)oxy]propoxy}benzene-1,3-diamine, 2-(2,4-diamino-phenyl)-ethanol, 2-(3-amino-4-methoxy-phenylamino)-ethanol, 4-(2-amino-ethoxy)-benzene-1,3-diamine, (2,4-diamino-phenoxy)-acetic acid, 2-[2,4-diamino-5-(2-hydroxy-ethoxy)-phenoxy]-ethanol, 4-ethoxy-6-methyl-benzene-1,3-diamine, 2-(2,4-diamino-5-methyl-phenoxy)-ethanol, 4,6-dimethoxy-benzene-1,3-diamine, 2-[3-(2-hydroxy-ethylamino)-2-methyl-phenylamino]-ethanol, 3-(2,4-diamino-phenoxy)-propan-1-ol, N-[3-(dimethylamino)phenyl]urea, 4-methoxy-6-methylbenzene-1,3-diamine, 4-fluoro-6-methylbenzene-1,3-diamine, 2-({3-[(2-hydroxyethyl)amino]4,6-dimethoxyphenyl}-amino)ethanol, 3-(2,4-diaminophenoxy)-propane-1,2-diol, 2-[2-amino-4-(methylamino)-phenoxy]ethanol, 2-[(5-amino-2-ethoxy-phenyl)-(2-hydroxy-ethyl)-amino]-ethanol, 2-[(3-aminophenyl)amino]ethanol, N-(2-aminoethyl)benzene-1,3-diamine, 4-{[(2,4-diamino-phenyl)oxy]methoxy}-benzene-1,3-diamine, and 2,4-dimethoxybenzene-1,3-diamine;
[0033] m-aminophenols such as: 3-amino-phenol, 2-(3-hydroxy-4-methyl-phenylamino)acetamide, 2-(3-hydroxy-phenylamino)-acetamide, 5-amino-2-methyl-phenol, 5-(2-hydroxy-ethylamino)-2-methyl-phenol, 5-amino-2,4-dichloro-phenol, 3-amino-2-methyl-phenol, 3-amino-2-chloro-6-methyl-phenol, 5-amino-2-(2-hydroxy-ethoxy)-phenol, 2-chloro-5-(2,2,2-trifluoro-ethylamino)-phenol, 5-amino-4-chloro-2-methyl-phenol, 3-cyclopentylamino-phenol, 5-[(2-hydroxyethyl)amino]-4-methoxy-2-methylphenol, 5-amino-4-methoxy-2-methylphenol, 3-(dimethylamino)phenol, 3-(diethylamino)phenol, 5-amino-4-fluoro-2-methylphenol, 5-amino4-ethoxy-2-methylphenol, 3-amino-2,4-dichloro-phenol, 3-[(2-methoxyethyl)amino]phenol, 3-[(2-hydroxyethyl)amino]phenol, 5-amino-2-ethyl-phenol, 5-amino-2-methoxyphenol, 5-[(3-hydroxypropyl)amino]-2-methylphenol, 3-[(3-hydroxy-2-methylphenyl)-amino]propane-1,2-diol, and 3-[(2-hydroxyethyl)amino]-2-methylphenol; and
[0034] heterocyclic derivatives such as: 3,4-dihydro-2H-1,4-benzoxazin-6-ol, 4-methyl-2-phenyl-2,4-dihydro-3H-pyrazol-3-one, 6-methoxyquinolin-8-amine, 4-methylpyridine-2,6-diol, 2,3-dihydro-1,4-benzodioxin-5-ol, 1,3-benzodioxol-5-ol, 2-(1,3-benzodioxol-5-ylamino)ethanol, 3,4-dimethylpyridine-2,6-diol, 5-chloropyridine-2,3-diol, 2,6-dimethoxypyridine-3,5-diamine, 1,3-benzodioxol-5-amine, 2-{[3,5-diamino-6-(2-hydroxy-ethoxy)-pyridin-2-yl]oxy}-ethanol, 1H-indol-4-ol, 5-amino-2,6-dimethoxypyridin-3-ol 1H-indole-5,6-diol, 1H-indol-7-ol, 1H-indol-5-ol, 1H-indol-6-ol, 6-bromo-1,3-benzodioxol-5-ol, 2-aminopyridin-3-ol, pyridine-2,6-diamine, 3-[(3,5-diaminopyridin-2-yl)oxy]propane-1,2-diol, 5-[(3,5-diaminopyridin-2-yl)oxy]pentane-1,3-diol, 1H-indole-2,3-dione, indoline-5,6-diol, 3,5-dimethoxypyridine-2,6-diamine, 6-methoxypyridine-2,3-diamine, and 3,4-dihydro-2H-1,4-benzoxazin-6-amine.
[0035] Preferred primary intermediates include:
[0036] p-phenylenediamine derivatives such as: 2-methyl-benzene-1,4-diamine, benzene-1,4-diamine, 1-(2,5-diamino-phenyl)-ethanol, 2-(2,5-diamino-phenyl)-ethanol, N-(2-methoxyethyl)benzene-1,4-diamine, 2-[(4-amino-phenyl)-(2-hydroxy-ethyl)-amino]-ethanol, and 1-(2,5-diaminophenyl)ethane-1,2-diol;
[0037] p-aminophenol derivatives such as 4-amino-phenol, 4-methylamino-phenol, 4-amino-3-methyl-phenol, 4-amino-2-methoxymethyl-phenol, and 1-(5-amino-2-hydroxy-phenyl)-ethane-1,2-diol;
[0038] o-aminophenol derivatives such as: 2-amino-phenol, 2-amino-5-methyl-phenol, 2-amino-6-methyl-phenol, N-(4-amino-3-hydroxy-phenyl)acetamide, and 2-amino-4-methyl-phenol; and
[0039] heterocyclic derivatives such as: pyrimidine-2,4,5,6-tetramine, 1-methyl-1H-pyrazole4,5-diamine, 2-(4,5-diamino-1H-pyrazol-1-yl)ethanol, 1-(4-methylbenzyl)-1H-pyrazole-4,5-diamine, 1-(benzyl)-1H-pyrazole-4,5-diamine, and N 2 ,N 2 -dimethyl-pyridine-2,5-diamine.
[0040] Preferred couplers include:
[0041] phenols, resorcinol and naphthol derivatives such as: naphthalene-1,7-diol, benzene-1,3-diol, 4-chlorobenzene-1,3-diol, naphthalen-1-ol, 2-methyl-naphthalen-1-ol, naphthalene-1,5-diol, naphthalene-2,7-diol, benzene-1,4-diol, 2-methyl-benzene-1,3-diol, and 2-isopropyl-5-methylphenol;
[0042] m-phenylenediamines such as: benzene-1,3-diamine, 2-(2,4-diamino-phenoxy)-ethanol, 4-{3-[(2,4-diaminophenyl)oxy]propoxy}benzene-1,3-diamine , 2-(3-amino4-methoxy-phenylamino)-ethanol, 2-[2,4-diamino-5-(2-hydroxy-ethoxy)-phenoxy]-ethanol, and 3-(2,4-diamino-phenoxy)-propan-1-ol;
[0043] m-aminophenols such as: 3-amino-phenol, 5-amino-2-methyl-phenol, 5-(2-hydroxy-ethylamino)-2-methyl-phenol, and 3-amino-2-methyl-phenol; and
[0044] heterocyclic derivatives such as: 3,4-dihydro-2H-1,4-benzoxazin-6-ol, 4-methyl-2-phenyl-2,4-dihydro-3H-pyrazol-3-one, 1,3-benzodioxol-5-ol, 1 ,3-benzodioxol-5-amine, 1H-indol-4-ol, 1H-indole-5,6-diol, 1H-indol-7-ol, 1H-indol-5-ol, 1H-indol-6-ol, 1H-indole-2,3-dione, pyridine-2,6-diamine, and 2-aminopyridin-3-ol.
[0045] Most preferred primary intermediates include:
[0046] p-phenylenediamine derivatives such as: 2-methyl-benzene-1,4-diamine, benzene-1,4-diamine, 2-(2,5-diamino-phenyl)-ethanol, 1-(2,5-diamino-phenyl)-ethanol, and 2-[(4-amino-phenyl)-(2-hydroxy-ethyl)-amino]-ethanol;
[0047] p-aminophenol derivatives such as: 4-amino-phenol, 4-methylamino-phenol, 4-amino-3-methyl-phenol, and 1-(5-amino-2-hydroxy-phenyl)-ethane-1,2-diol;
[0048] o-aminophenols such as: 2-amino-phenol, 2-amino-5-methyl-phenol, 2-amino-6-methyl-phenol, and N-(4-amino-3-hydroxy-phenyl)-acetamide; and
[0049] heterocyclic derivatives such as: pyrimidine-2,4,5,6-tetramine, 2-(4,5-diamino-1H-pyrazol-1-yl)ethanol, 1-(4-methylbenzyl)-1H-pyrazole-4,5-diamine, and 1-(benzyl)-1H-pyrazole4,5-diamine.
[0050] Most preferred couplers include:
[0051] phenols, resorcinol and naphthol derivatives such as: benzene-1,3-diol, 4-chlorobenzene-1,3-diol, naphthalen-1-ol, 2-methyl-naphthalen-1-ol, and 2-methyl-benzene-1,3-diol;
[0052] m-phenylenediamine such as: 2-(2,4-diamino-phenoxy)-ethanol, 2-(3-amino4-methoxy-phenylamino)-ethanol, 2-[2,4-diamino-5-(2-hydroxy-ethoxy)-phenoxy]-ethanol, and 3-(2,4-diamino-phenoxy)-propan-1-ol;
[0053] m-aminophenols such as: 3-amino-phenol, 5-amino-2-methyl-phenol, 5-(2-hydroxy-ethylamino)-2-methyl-phenol, and 3-amino-2-methyl-phenol; and
[0054] heterocyclic derivatives such as: 3,4-dihydro-2H-1,4-benzoxazin-6-ol, 4-methyl-2-phenyl-2,4-dihydro-3H-pyrazol-3-one, 1H-indol-6-ol, and 2-aminopyridin-3-ol.
[0055] Understandably, the coupler compounds and the primary intermediate compounds, including the novel compounds of the invention, in so far as they are bases, can be used as free bases or in the form of their physiologically compatible salts with organic or inorganic acids, such as hydrochloric, citric, acetic, tartaric, or sulfuric acids, or, in so far as they have aromatic OH groups, in the form of their salts with bases, such as alkali phenolates.
[0056] The total amount of dye precursors (e.g., primary intermediate and coupler compounds, including the novel compounds of this invention) in the hair dyeing compositions of this invention is generally from about 0.002 to about 20, preferably from about 0.04 to about 10, and most preferably from about 0.1 to about 7.0 weight percent, based on the total weight of the hair dyeing composition. The primary intermediate and coupler compounds are generally used in molar equivalent amounts. However, it is possible to use the primary intermediate compounds in either excess or deficiency, i.e., a molar ratio of primary intermediate to coupler generally ranging from about 5:1 to about 1:5.
[0057] The hair dyeing compositions of this invention will contain the primary intermediate of this invention in an effective dyeing amount, generally in an amount of from about 0.001 to about 10 weight percent by weight of the hair dye composition, preferably from about 0.01 to about 5.0 weight percent. Other primary intermediates, when present, are typically present in an amount such that in aggregate the concentration of primary intermediates in the composition is from about 0.002 to about 10 weight percent, preferably from about 0.01 to about 5.0 weight percent. The coupler(s) are present in an effective dyeing concentration, generally an amount of from about 0.001 to about 10.0 weight percent by weight of the hair dye composition, preferably from about 0.01 to about 5.0 weight percent. The remainder of the hair dye composition comprises a carrier or vehicle for the couplers and primary intermediates, and comprises various adjuvants as described below.
[0058] Any suitable carrier or vehicle, generally an aqueous or hydroalcoholic solution, can be employed, preferably an aqueous solution. The carrier or vehicle will generally comprise more than 80 weight percent of the hair dye composition, typically 90 to 99 weight percent, preferably 94 to 99 weight percent. The hair coloring compositions of this invention may contain as adjuvants one or more cationic, anionic, amphoteric, or zwitterionic surface active agents, perfumes, antioxidants such as ascorbic acid, thioglycolic acid or sodium sulfite, chelating and sequestering agents such as EDTA, thickening agents, alkalizing or acidifying agents, solvents, diluents, inerts, dispersing agents, penetrating agents, defoamers, enzymes, and other dye agents (e.g., synthetic direct and natural dyes). These adjuvants are cosmetic additive ingredients commonly used in compositions for coloring hair.
[0059] The hair dye compositions of the present invention are used by admixing them with a suitable oxidant, which reacts with the hair dye precursors to develop the hair dye. Any suitable oxidizing agent can be employed in the hair dye product compositions of this invention, particularly hydrogen peroxide (H 2 O 2 ) or precursors therefor. Also suitable are urea peroxide, the alkali metal salts of persulfate, perborate, and percarbonate, especially the sodium salt, and melamine peroxide. The oxidant is usually provided in an aqueous composition generally referred to as the developer composition, which normally is provided as a separate component of the finished hair dye product and present in a separate container. The developer composition may also contain, to the extent compatible, various ingredients needed to form the developer composition, i.e., peroxide stabilizers, foam formers, etc., and may incorporate one or more of the adjuvants referred to above, e.g., surface active agents, thickeners, pH modifiers, etc. Upon mixing the hair coloring composition and the developer composition to form a hair dye product composition, the adjuvants are provided in the hair dye product composition as it is applied to the hair to achieve desired product attributes, e.g., pH, viscosity, rheology, etc.
[0060] The form of the hair dye product compositions according to the invention can be, for example, a solution, especially an aqueous or aqueous-alcoholic solution. However, the form that is preferred is a thick liquid cream, gel or an emulsion whose composition is a mixture of the dye ingredients with the conventional cosmetic additive ingredients suitable for the particular preparation.
[0061] Suitable conventional cosmetic additive ingredients useful in the hair dye and developer compositions, and hence in the hair dye product compositions of this invention are described below, and may be used to obtain desired characteristics of the hair dye, developer, and hair dye product compositions. Solvents: In addition to water, solvents that can be used are lower alkanols (e.g., ethanol, propanol, isopropanol, benzyl alcohol); polyols (e.g., carbitols, propylene glycol, hexylene glycol, glycerin). See WO 98/27941 (section on diluents) incorporated by reference. See also US 6027538 incorporated by reference. Under suitable processing, higher alcohols, such as C8 to C18 fatty alcohols, especially cetyl alcohol, are suitable organic solvents, provided they are first liquified by melting, typically at low temperature (50 to 80° C.), before incorporation of other, usually lipophilic, materials.
[0062] The organic solvents are typically present in the hair dye compositions in an amount of from about 5 to about 30% by weight of the hair dye composition. Water is usually present in an amount of from about 5 to about 90% by weight of the hair dye composition, preferably from about 15 to about 75% by weight and most preferably from about 30 to about 65% by weight.
[0063] Surfactants: These materials are from the classes of anionic, cationic, amphoteric (including zwitterionic surfactants) or nonionic surfactant compounds. (Cationic surfactants, generally included as hair conditioning materials, are considered separately below.) Suitable surfactants, other than cationic surfactants, include fatty alcohol sulfates, ethoxylated fatty alcohol sulfates, alkylsulfonates, alkylbenzensulfonates, alkyltrimethylammonium salts, alkylbetaines, ethoxylated fatty alcohols, ethoxylated fatty acids, ethoxylated alkylphenols, block polymers of ethylene and/orpropylene glycol, glycerol esters, phosphate esters, fatty acid alkanol amides and ethoxylated fatty acid esters, alkyl sulfates, ethoxylated alkyl sulfates, alkyl glyceryl ether sulfonates, methyl acyl taurates, acyl isethionates, alkyl ethoxy carboxylates, fatty acid mono- and diethanolamides. Especially useful are sodium and ammonium alkyl sulfates, sodium and ammonium ether sulfates having 1 to 3 ethylene oxide groups, and nonionic surfactants sold as Tergitols, e.g., C11-C15 Pareth-9, and Neodols, e.g., C12-C15 Pareth-3. They are included for various reasons, e.g., to assist in thickening, for forming emulsions, to help in wetting hair during application of the hair dye product composition, etc. Amphoteric surfactants include, for example, the asparagine derivatives as well betaines, sultaines, glycinates and propionates having an alkyl or alkylamido group of from about 10 to about 20 carbon atoms. Typical amphoteric surfactants suitable for use in this invention include lauryl betaine, lauroamphoglycinate, lauroamphopropionate, lauryl sultaine, myristamidopropyl betaine, myristyl betaine, stearoamphopropylsulfonate, cocamidoethyl betaine, cocamidopropyl betaine, cocoamphoglycinate, cocoamphocarboxypropionate, cocoamphocarboxyglycinate, cocobetaine, and cocoamphopropionate. Reference is made to WO 98/52523 published Nov. 26, 1998 and WO 01/62221 published Aug. 30, 2001, both incorporated herein by reference thereto.
[0064] The amount of surfactants in the hair dye compositions is normally from about 0.1% to 30% by weight, preferably 1% to 15% by weight.
[0065] Thickeners: Suitable thickeners include such as higher fatty alcohols, starches, cellulose derivatives, petrolatum, paraffin oil, fatty acids and anionic and nonionic polymeric thickeners based on polyacrylic and polyurethane polymers. Examples are hydroxyethyl cellulose, hydroxymethylcellulose and other cellulose derivatives, hydrophobically modified anionic polymers and nonionic polymers, particularly such polymers having both hydrophilic and hydrophobic moieties (i.e., amphiphilic polymers). Useful nonionic polymers include polyurethane derivatives such as PEG-150/stearyl alcohol/SDMI copolymer. Suitable polyether urethanes are Aculyn® 44 and Aculyn® 46 polymers sold by Rohm & Haas. Other useful amphiphilic polymers are disclosed in U.S. Pat. No. 6,010,541 incorporated by reference. See also WO 01/62221 mentioned above. Examples of anionic polymers that can be used as thickeners are acrylates copolymer, acrylates/ceteth-20 methacrylates copolymer, acrylates/ceteth-20 itaconate copolymer, and acrylates/beheneth-25 acrylates copolymers. In the case of the associative type of thickeners, e.g., Aculyns 22, 44 and 46, the polymer may be included in one of either the hair dye composition or the developer composition of the hair dye product and the surfactant material in the another. Thus, upon mixing of the hair dye and developer compositions, the requisite viscosity is obtained. The thickeners are provided in an amount to provide a suitably thick product as it is applied to the hair. Such products generally have a viscosity of from 1000 to 100000 cps, and often have a thixotropic rheology.
[0066] pH Modifying agents: Suitable materials that are used to adjust pH of the hair dye compositions include alkalizers such alkali metal and ammonium hydroxides and carbonates, especially sodium hydroxide and ammonium carbonate, ammonia, organic amines including methylethanolamine, aminomethylpropanol, mono-, di-, and triethanolamine, and acidulents such as inorganic and inorganic acids, for example phosphoric acid, acetic acid, ascorbic acid, citric acid or tartaric acid, hydrochloric acid, etc. See U.S. Pat. No. 6,027,538 incorporated by reference.
[0067] Conditioners: Suitable materials include silicones and silicone derivatives; hydrocarbon oils; monomeric quaternary compounds, and quaternized polymers. Monomeric quaternary compounds are typically cationic compounds, but may also include betaines and other amphoteric and zwitterionic materials that provide a conditioning effect. Suitable monomeric quaternary compounds include behentrialkonium chloride, behentrimonium chloride, benzalkonium bromide or chloride, benzyl triethyl ammonium chloride, bis-hydroxyethyl tallowmonium chloride, C12-18 dialkyldimonium chloride, cetalkonium chloride, ceteartrimonium bromide and chloride, cetrimonium bromide, chloride and methosulfate, cetylpyridonium chloride, cocamidoproypl ethyidimonium ethosulfate, cocamidopropyl ethosulfate, coco-ethyldimonium ethosulfate, cocotrimonium chloride and ethosulfate, dibehenyl dimonium chloride, dicetyldimonium chloride, dicocodimonium chloride, dilauryl dimonium chloride, disoydimonium chloride, ditallowdimonium chloride, hydrogenated tallow trimonium chloride, hydroxyethyl cetyl dimonium chloride, myristalkonium chloride, olealkonium chloride, soyethomonium ethosulfate, soytrimonium chloride, stearalkonium chloride, and many other compounds. See WO 98/27941 incorporated by reference. Quaternized polymers are typically cationic polymers, but may also include amphoteric and zwitterionic polymers. Useful polymers are exemplified by polyquaternium-4, polyquaternium-6, polyquaternium-7, polyquaternium-8, polyquaternium-9, polyquaternium-10, polyquaternium-22, polyquatemium-32, polyquaternium-39, polyquaternium-44 and polyquatemium-47. Silicones suitable to condition hair are dimethicone, amodimethicone, dimethicone copolyol and dimethiconol. See also WO 99/34770 published Jul. 15, 1999, incorporated by reference, for suitable silicones. Suitable hydrocarbon oils would include mineral oil.
[0068] Conditioners are usually present in the hair dye composition in an amount of from about 0.01 to about 5% by weight of the hair dye composition.
[0069] Direct Dyes: The hair dyeing compositions according to the invention can also contain compatible direct dyes including Disperse Black 9, HC Yellow 2, HC Yellow 4, HC Yellow 15, 4-nitro-o-phenylenediamine, 2-amino-6-chloro-4-nitrophenol, HC Red 3, Disperse Violet 1, HC Blue 2, Disperse Blue 3, and Disperse Blue 377. These direct dyes can be contained in the hair coloring compositions of the invention in an amount of from about 0.05 to 4.0 percent by weight.
[0070] Natural ingredients: For example, proteins and protein derivatives, and plant materials such as aloe, chamomile and henna extracts.
[0071] Other adjuvants include polysaccharides, alkylpolyglycosides, buffers, chelating and sequestrant agents, antioxidants, and peroxide stabilizing agents as mentioned in WO 01/62221, etc.
[0072] The adjuvants referred to above but not specifically identified that are suitable are listed in the International Cosmetics Ingredient Dictionary and Handbook, (Eighth Edition) published by The Cosmetics, Toiletry, and Fragrance Association, incorporated by reference. In particular reference is made to Volume 2, Section 3 (Chemical Classes) and Section 4 (Functions) are useful in identifying a specific adjuvant to achieve a particular purpose or multipurpose.
[0073] The above-mentioned conventional cosmetic ingredients are used in amounts suitable for their functional purposes. For example, the surfactants used as wetting agents, associative agents, and emulsifiers are generally present in concentrations of from about 0.1 to 30 percent by weight, the thickeners are useful in an amount of from about 0.1 to 25 percent by weight, and the hair care materials are typically used in concentrations of from about 0.01 to 5.0 percent by weight.
[0074] The hair dyeing product composition as it is applied to the hair, i.e., after mixing the hair dye composition according to the invention and the developer, can be weakly acidic, neutral or alkaline according to their composition. The hair dye compositions can have pH values of from about 6 to 11.5, preferably from about 6.8 to about 10, and especially from about 8 to about 10. The pH of the developer composition is typically acidic, and generally the pH is from about 2.5 to about 6.5, usually about 3 to 5. The pH of the hair dye and developer compositions is adjusted using a pH modifier as mentioned above.
[0075] In order to use the hair coloring composition for dyeing hair, the above-described hair coloring compositions according to the invention are mixed with an oxidizing agent immediately prior to use and a sufficient amount of the mixture is applied to the hair, according to the hair abundance, generally from about 60 to 200 grams. Some of the adjuvants listed above (e.g., thickeners, conditioners, etc.) can be provided in the dye composition or the developer, or both, depending on the nature of the ingredients, possible interactions, etc., as is well known in the art.
[0076] Typically, hydrogen peroxide, or its addition compounds with urea, melamine, sodium borate or sodium carbonate, can be used in the form of a 3 to 12 percent, preferably 6 percent, aqueous solution as the oxidizing agent for developing the hair dye. Oxygen can also be used as the oxidizing agent. If a 6 percent hydrogen peroxide solution is used as oxidizing agent, the weight ratio of hair coloring composition and developer composition is 5:1 to 1:5, but preferably 1:1. In general, the hair dyeing composition comprising primary intermediate(s) and coupler(s), including at least one of the compounds of formula (1), is prepared and then, at the time of use, the oxidizing agents, such as H 2 O 2 , contained in a developer composition is admixed therewith until an essentially homogenous composition is obtained, which is applied shortly after preparation to the hair to be dyed and permitted to remain in contact with the hair for a dyeing effective amount of time. The mixture of the oxidizing agent and the dye composition of the invention (i.e., the hair dye product composition) is allowed to act on the hair for about 2 to about 60 minutes, preferably about 15 to 45, especially about 30 minutes, at about 15 to 50° C., the hair is rinsed with water, and dried. If necessary, it is washed with a shampoo and rinsed, e.g., with water or a weakly acidic solution, such as a citric acid or tartaric acid solution. Subsequently the hair is dried. Optionally, a separate conditioning product may also be provided.
[0077] Together the hair dye composition of the present invention comprising the hair dye primary intermediate (1) and the developer composition comprising the oxidizing agent form a system for dyeing hair. This system may be provided as a kit comprising in a single package separate containers of the hair dye composition, the developer, the optional conditioner or other hair treatment product, and instructions for use.
[0078] Especially useful primary intermediates of formula (1) of this invention will provide hair coloring compositions having outstanding color fastness, especially light fastness, fastness to washing and fastness to rubbing.
Dyeing Example 1
[0079] The following composition shown in Table 1 can be used for dyeing Piedmont hair. 100 g of the dyeing composition is mixed with 100 g 20 volume hydrogen peroxide. The resulting mixture is applied to the hair and permitted to remain in contact with the hair for 30 minutes. The dyed hair is then shampooed, rinsed with water and dried. The ranges of ingredients set out in Table 1 are illustrative of useful concentrations of the recited materials in a hair dye product.
TABLE 1 Composition for Dyeing Hair Ingredients Range (wt %) Weight (%) Cocamidopropyl betaine 0-25 17.00 Polyquaternium-22 0-7 5.00 Monoethanolamine 1 0-15 2.00 Oleic Acid 2-22 0.75 Citric Acid 0-3 0.10 28% Ammonium hydroxide 1 0-15 5.00 Behentrimonium chloride 1-5 0.50 Sodium sulfite 0-1 0.10 EDTA 0-1 0.10 Erythorbic acid 0-1 0.40 Ethoxydiglycol 1-10 3.50 C11-15 Pareth-9 (Tergitol 15-S-9) 0.5-5 1.00 C12-15 Pareth-3 (Neodol 25-3) 0.25-5 0.50 Isopropanol 2-10 4.00 Propylene glycol 1-12 2.00 p-phenylenediamine 0-5 1 mmole N,N-Bis(hydroxyethyl)-p-phenylene 0-5 1 mmole diamine 3-Methyl-p-aminophenol 0-5 1 mmole p-Aminophenol 0-5 1 mmole Primary Intermediate of this invention 0.5-5 4 mmoles 5-Amino-2-Methyl Phenol 2 0-5 3 mmoles 2,4-Diaminophenoxyethanol 2 0-5 3 mmoles M-Phenylenediamine 2 0-5 1 mmole Water qs to 100.00 qs to 100.00
[0080] Exemplary combinations of hair coloring components employing a novel primary intermediate of formula (1) of this invention are shown in Table 1 and in combinations C1 to C136 in Tables A through H. Reading down the columns in e.g., Table A, the Xes designate the dye compounds (including the novel primary intermediates of the instant invention) that form illustratively suitable combinations of dyes that can be formulated according to the present invention. For example, in Combination No. C1 in Column 4 of Table A, a primary intermediate of Formula 1 of this invention, wherein R 1 and R 2 are defined hereinbefore, can be combined with 2-amino-phenol.
[0081] Especially preferred as the primary intermediates in Table 1 and in combinations C1 to C136 of Tables A through H are:
[0082] 4-amino-2-(2-dimethylamino-ethyl)-phenol;
[0083] 4-amino-2-(3-dimethylamino-propyl)-phenol;
[0084] 4-amino-2-(2-diethylamino-ethyl)-phenol;
[0085] 4-amino-2-(3-diethylamino-propyl )-phenol;
[0086] 4-amino-2-(3-amino-propyl)-phenol;
[0087] 4-amino-2-(2-piperidin-1-ylethyl)-phenol;
[0088] 4-amino-2-(3-piperidin-1-ylpropyl)-phenol;
[0089] 4-amino-2-[2-(pyridin-3-ylamino)ethyl]-phenol;
[0090] 4-amino-2-(2-imidazol-1-ylethyl)-phenol;
[0091] 4-amino-2-(2-morpholin-1-ylethyl)-phenol; and
[0092] 4-amino-2-[2-(2-hydroxyethylamino)-ethyl]-phenol.
TABLE A Dye Combinations Structure IUPAC Name Name C1 C2 X X 2-Methyl-benzene-1,4- diamine p-Toluene-diamine Benzene-1,4-diamine p-Phenylene-diamine 2-[(4-Amino-phenyl)-(2- hydroxy-ethyl)-amino]- ethanol N,N-Bis(2-hydroxyethyl)- p-phenylene-diamine 1-(2,5-Diamino-phenyl)- ethanol 1-Hydroxyethyl-p- phenylenediamine 4-Amino-3-methyl- phenol 3-Methyl-p-aminophenol 2-Amino-phenol o-Aminophenol X Benzene-1,3-diol Resorcinol X 2-Methyl-benzenele-1,3- diol 2-Methyl-resorcinol Naphthalen-1-ol 1-Naphthol 2-Methyl-naphthalen-1- ol 2-Methyl-1-naphthol 2-(2,4-Diamino- phenoxy)-ethanol 2,4-Diamino- phenoxyethanol Benzene-1,3-diamine m-Phenylenediamine 3-Amino-phenol m-Aminophenol 5-Amino-2-methyl- phenol 2-Hydroxy-4- aminotoluene 2-(4,5-Diamino-pyrazol- 1-yl)-ethanol 1-Hydroxyethyl-4,5- diamino-pyrazole Structure C3 C4 C5 C6 C7 C8 C9 C10 C11 X X X X X X X X X X X X X X X X X X X
[0093] [0093] TABLE B Dye Combinations Structure C12 C13 C14 C15 C16 C17 C18 C19 C20 X X X X X X X X X X X X X X X X X X X X X X X X X X X Structure C21 C22 C23 C24 C25 C26 C27 C28 C29 X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X
[0094] [0094] TABLE C Dye Combinations Structure C30 C31 C32 C33 C34 C35 C36 C37 C38 X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X Structure C39 C40 C41 C42 C43 C44 C45 C46 C47 X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X
[0095] [0095] TABLE D Dye Combinations Structure C48 C49 C50 C51 C52 C53 C54 C55 C56 X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X Structure C57 C58 C59 C60 C61 C62 C63 C64 C65 X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X
[0096] [0096] TABLE E Dye Combinations Structure C66 C67 C68 C69 C70 C71 C72 C73 C74 X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X Structure C75 C76 C77 C78 C79 C80 C81 C82 C83 X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X
[0097] [0097] TABLE F Dye Combinations Structure C84 C85 C86 C87 C88 C89 C90 C91 C92 X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X Structure C93 C94 C95 C96 C97 C98 C99 C100 C101 X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X
[0098] [0098] TABLE G Dye Combinations Structure C102 C103 C104 C105 C106 C107 C108 C109 C110 X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X x x Structure C111 C112 C113 C114 C115 C116 C117 C118 C119 X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X x x x x x x x x x
[0099] [0099] TABLE H Dye Combinations Structure C120 C121 C122 C123 C124 C125 C126 C127 C128 X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X x x x x x x x x x Structure C129 C130 C131 C132 C133 C134 C135 C136 X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X x x x x x x x x
[0100] With the foregoing description of the invention, those skilled in the art will appreciate that modifications may be made to the invention without departing from the spirit thereof. Therefore, it is not intended that the scope of the invention be limited to the specific embodiments illustrated and described. | Primary intermediates for hair coloring compositions for oxidative dyeing of hair are compounds of the formula (1):
wherein R 1 and R 2 are each independently selected from hydrogen atoms, a C 1 to C 5 alkyl or hydroxyalkyl group, or R 1 and R 2 together with the nitrogen atom to which they are attached form a 5 or 6 member cyclic ring optionally containing one or more additional atoms selected from O, N or S atoms, and n is equal to 1 or 2, with the proviso that when n is equal to 2 only one of R 1 and R 2 may be hydrogen. | 2 |
CROSS REFERENCE TO RELATED APPLICATIONS
This Application is related to and claims priority to U.S. Provisional Application No. 62/077,522, entitled “Modular Boat Lift Cover”, by Eric N. Nelson filed on Nov. 10, 2014.
FIELD OF USE
The present invention relates to a modular boat lift cover system which is designed for ease of shipping and assembly as well as adjustability as the lift owner changes or modifies their boat. The modular boat lift cover being unique in that it can accommodate all boat lifts that are square, such as lake lifts, as well as tidal lifts which, due to their nature of construction, are seldom square.
BACKGROUND OF THE INVENTION
A watercraft represents a significant investment. Watercraft owners store their boats on lifts understand that a boat lift cover or canopy is needed to minimize the maintenance work required to maintain the appearance of the boat. Watercraft owners need to shelter docked boats from the elements to preserve the life of the boat. While boat houses can provide such shelter, they are expensive, often impractical and, under some circumstances, not allowed by code. Watercraft owners also need to lift their watercraft out of the water for storage and maintenance, and to lower their watercraft into the water for launching or flotation at dock. There are typically two types of boat lifts: lake lifts and tidal lifts. A lake lift is typically manufactured as a complete frame system that is lowered into the water as a single unit and fastened to the lake floor. It remains square due to the calmness of inland water. Tidal lifts are typically constructed on site with a barge pounding long pilings into the sea floor onto which the boat lift mechanism is then mounted. This construction technique is subject to tidal forces during the time that the pilings are being hammered into the sea floor, which can cause the lift to be not perfectly square. Additionally, each boat lift manufacturer has its own design for the lifting I-beam, the cable system and the position of the electric motors making it difficult to design, manufacture and install a boat lift cover for tidal lifts.
Prior approaches use many different parts, while shipping in multiple boxes, or one large box. They also require complex assembly procedures and are not adjustable depending on the size of the watercraft.
U.S. Pat. No. 5,185,972 (Markiewicz) discloses an all-purpose modular canopy system including a canopy frame formed of a plurality of interconnected sections, the sections being formed of welded tubular elements. The sections are modular in configuration including end and central portions whereby the sections may be selectively assembled to produce the desired length. The canopy frame includes transversely disposed brace elements associated with supporting columns and adjustable fittings to facilitate alignment of the columns and canopy frame, and the canopy frame is covered by a flexible covering using a lacing system between the frame and covering to maintain covering tension. The covering may include a skirt cooperating with skirt stabilizers formed in the canopy frame corners for maintaining the skirt properly oriented. U.S. Publication No. 20050252542 (Basta) discloses a boat lift canopy comprises a truss type framework with a base frame. Joined to the base frame and circumscribed by it is a tie tube frame, which may be discontinuous. A fabric cover, which in preferred embodiments is decorative as well as functional, snugly encloses the outside of the framework, wraps around the base frame and is secured to the tie tube frame. U.S. Pat. No. 5,573,026 (Griffith) discloses a pre-fabricated boat lift canopy constructed of galvanized steel or aluminum tubing. All joints are crimped to a tight, permanent fit by using a special rolling tool. The canopy frame is mounted on “I” beams of existing boat lifts, docks, or pilings. The canopy frame is then covered with a water tight and sunlight resistant decorative canopy. Wind spoilers, in the form of canvas strips, are fastened to the peak of the canopy, a continuous strip, horizontally across the top, a strip at each end, and a third strip at the center. U.S. Pat. No. 5,730,281 (Powell, et al.) discloses a canopy kit comprising a plurality of elongated pipes and a series of corner connectors and a package for containing the various kit components. An elongated container is provided and the various components of the kit, including the corner connectors and pipes, are disposed within the container such that the components of the kit structurally reinforce the total package and wherein the individual corner connectors are strategically disposed throughout the package so as to support the elongated pipes.
The packaging of boat lift covers and canopies currently being marketed is overly-complicated and costly, and assembly is difficult to explain even with instructions. In order to communicate the intricacies of assembly and disassembly, personal demonstrations are often required. In some cases, multiple training sessions are needed. If the complicated unpacking was not difficult enough, the procedure for layout and assembly of the frame is oftentimes even more complex. In addition to the difficulty of assembly, current boat lift covers cannot be easily adjusted if the lift owner modifies his boat, such as by adding a tower, or replaces his boat with, for example, a larger boat. Current boat lift cover designs have some degree of adjustability but are not adjustable enough to easily accommodate all boat lift mechanisms and the dimensional tolerance variations of tidal lifts.
There is a need for a modular boat lift cover system that is easier to manufacture, package, assemble and disassemble. There is a need for a modular boat lift cover system that has a robust, lightweight design that is compatible and adjustable for width, height and length as the boat owner modifies his existing boat or purchases a new boat of different dimensions, and that will protect the watercraft from the elements and is designed to withstand even the severest of storms, undamaged. There is also a need for an adjustable boat lift cover that will work with any manufacturer's boat lift and will accommodate the variation in build tolerances of tidal lifts.
It is an object of the present invention to provide a compact, all-weather, temporary shelter designed for both personnel and equipment. It is another object of the present invention to provide a modular boat lift cover that is easy to pack and assemble. All of the straight components are packaged into the main box frame channel for simplicity in packaging as well as quality control, ensuring no components are missing during packaging and shipping. It is yet another object of the present invention to provide a modular boat lift cover that is easy for the user to assemble and adjust, is intuitive and requires little training to adjust the canopy to different widths, lengths and heights both upon initial installation as well as during the life of the lift cover, enabling for the lift owner to accommodate modifications to his existing boat as well as to accommodate new boats of different dimensions. And, it is still yet another object of the present invention to provide a modular boat lift cover that is easy for the user to assemble and adjust, being compatible with square lake style boat lifts, as well as the typically non-square tidal lifts.
SUMMARY OF THE INVENTION
The modular boat lift cover of the present invention addresses these needs.
The modular boat lift cover of the present invention comprises a gable assembly of straight tubes, a canopy, and an adjustable support structure to accommodate the height of various watercraft.
The gable assembly includes a plurality of peak fittings, a plurality of box frame support members, a plurality of pipe fittings disposed on the box frame support members, and a plurality of tubes securely attaching the peak fittings to the box frame support members enabling for either a straight or curved roof design as well as no overhang or various lengths of overhang, depending on the customer's preference.
The plurality of peak fittings are positioned between the box frames and a peak fitting connector tube of the gable assembly, the peak fitting connector tube being connected by at least one end peak fitting.
The plurality of box frame support members are preferably two parallel members, although other configurations are also envisioned. Preferably, the plurality of box support members is essentially parallel to the peak fitting connector tube. The peak fittings, the peak fitting connector tube, and additional connectors and fasteners can be stored inside the plurality of box frame support members during shipping.
The plurality of tubes are used as needed to attach the peak fittings to the box frame and to lay a foundation for the canopy. The plurality of tubes securely attach the peak fitting connectors to the box frame support members by engaging with the plurality of pipe fittings.
The canopy covers the gable assembly protecting the watercraft from the sun, rain and storms, the canopy being securely affixed to the gable assembly.
An adjustable support structure enables elevation and lowering of portions of the gable assembly of the modular boat lift cover of the present invention. The support structure is compatible with a wide variety of modular boat lift covers.
The gable assembly is supported upon the adjustable support structure which includes a plurality of beam brackets and a plurality of support columns, each support column being disposed within a beam bracket. The adjustable support structure provides a vertical adjustment for portions or all of the gable assembly.
All of the length, width and height assemble points are designed to have a wide range of adjustment. This wide range of adjustment is what enables the modular boat lift cover of the present invention to accommodate boat lifts from any manufacturer as well as accommodating square lake lifts and out-of-square tidal lifts. In addition, the range of adjustment enables for easy configuration for different sizes of watercraft.
The modular boat lift cover of the present invention combines the advantages is a portable structure which in its collapsed state forms a standard shipping container for ease of transport.
The box frames of the modular boat lift cover of the present invention serves as shipping containers and modular building blocks for expanding the modular boat lift cover to adapt to a completely different watercraft purchased by the owner.
For a complete understanding of the modular boat lift cover of the present invention, reference is made to the accompanying drawings and description in which the presently preferred embodiments of the invention are shown by way of example. As the invention may be embodied in many forms without departing from spirit of essential characteristics thereof, it is expressly understood that the drawings are for purposes of illustration and description only, and are not intended as a definition of the limits of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 depicts a first preferred embodiment of an assembly side view of the modular boat lift cover of the present invention.
FIG. 2A depicts an assembly end view of the preferred embodiment of a gable assembly for the modular boat lift cover of the present invention of FIG. 1 .
FIG. 2B depicts a preferred embodiment of an end view of the gable assembly of FIG. 1 mounted on a pair of support columns and beam brackets.
FIG. 2C depicts a preferred embodiment of an end view of the gable assembly of FIG. 1 mounted on a pair of upper brackets, centered brackets and variable centered brackets.
FIG. 2D depicts an exploded view of a preferred embodiment of an end view of the gable assembly of FIG. 1 attached to a pair of support columns with U-bolts, and a pair of beam brackets secured to I-beams with beam clamps.
FIG. 3 depicts an assembly side view of a second preferred embodiment the modular boat lift cover of the present invention, the tube members being curved.
FIG. 4A depicts an assembly end view of a gable assembly for the modular boat lift cover of FIG. 3 .
FIG. 4B depicts a preferred embodiment of an end view of the curved gable assembly of FIG. 4A mounted on a pair of support columns and beam brackets.
FIG. 4C depicts a preferred embodiment of an end view of the curved gable assembly of FIG. 4A mounted on a pair of upper brackets, centered brackets and variable centered brackets.
FIG. 4D depicts a preferred embodiment of an end view of the curved gable assembly of FIG. 4A attached to a pair of support columns with U-bolts, and a pair of beam brackets secured to I-beams with beam clamps.
FIG. 5A depicts a preferred embodiment of the front view of the end peak fitting for the modular boat lift cover of FIGS. 1 and 3 .
FIG. 5B depicts a preferred embodiment of the front view of the internal peak fitting for the modular boat lift cover of FIGS. 1 and 3 .
FIG. 5C depicts a preferred embodiment of the side view of the end peak fitting of FIG. 5A .
FIG. 5D depicts a preferred embodiment of the side view of the internal peak fitting of FIG. 5B .
FIG. 5E depicts a preferred embodiment of the top view of the end overhang fitting for the modular boat lift cover of FIG. 3 .
FIG. 5F depicts a preferred embodiment of the top view of the internal overhang fitting for the modular boat lift cover of FIG. 3 .
FIG. 6A depicts a preferred embodiment of a side view of the box frame of for the modular boat lift cover of FIG. 1 .
FIG. 6B depicts a preferred embodiment of a simplified end view of the box frame engagement with a pipe fitting of the gable assembly of the modular boat lift of FIGS. 2A , 2 B and 2 C.
FIG. 6C depicts a preferred embodiment of a typical exploded front view of the box frame engagement with a pipe fitting of the gable assembly of the modular boat lift cover of FIGS. 2A , 2 B and 2 C.
FIG. 6D depicts an isometric view of a preferred embodiment of the box frame splice assembly of the modular boat lift cover of FIG. 1 .
FIG. 7A depicts a preferred embodiment of a simplified top view of a beam bracket of the modular boat lift cover of FIGS. 1 and 3 .
FIG. 7B depicts a preferred embodiment of a simplified side view of a beam bracket of the modular boat lift cover of FIGS. 1 and 3 .
FIG. 7C depicts a preferred embodiment of a simplified front view of a beam bracket of the modular boat lift cover of FIGS. 1 and 3 .
FIG. 8A depicts a preferred embodiment of a simplified top view of a support column of the modular boat lift cover of FIGS. 1 and 3 .
FIG. 8B depicts a preferred embodiment of a simplified side view of a support column of the modular boat lift cover of FIGS. 1 and 3 .
FIG. 8C depicts a preferred embodiment of a simplified front view of a support column of the modular boat lift cover of FIGS. 1 and 3 .
FIG. 9A depicts a preferred embodiment of the end view of the upper bracket for the centered bracket of FIG. 1 .
FIG. 9B depicts a preferred embodiment of the side view of the upper bracket for the centered bracket of FIG. 1 .
FIG. 9C depicts a preferred embodiment of the front view of the upper bracket for the centered bracket of FIG. 1 .
FIG. 10A depicts a preferred embodiment of the end view of the variable centered bracket for the centered bracket of FIG. 1 .
FIG. 10B depicts a preferred embodiment of the side view of the variable centered bracket for the centered bracket of FIG. 1 .
FIG. 10C depicts a preferred embodiment of the front view of the variable centered bracket for the centered bracket of FIG. 1 .
FIG. 11 depicts a plurality of tubes packaged inside a box frame of the gable assembly for the modular boat lift covers of FIGS. 1 and 3 .
FIG. 12 depicts an isometric view of a preferred embodiment of the box frame end cap and box frame of the modular boat lift covers of FIGS. 1 and 3 .
FIG. 13A depicts one preferred embodiment for attaching the canopy to the box frame of the boat lift cover of FIGS. 1 and 2A .
FIG. 13B depicts one preferred embodiment for attaching the canopy to the box frame of the boat lift cover of FIGS. 3 and 4A .
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring now to the drawings, FIG. 1 depicts a preferred embodiment of an assembly side view of the modular boat lift cover of the present invention [ 10 ].
The modular boat lift cover of the present invention [ 10 ] comprises a gable assembly [ 13 ], a canopy [ 16 ], and an adjustable support structure [ 20 ] for a watercraft.
The gable assembly [ 13 ] includes a plurality of end peak fittings [ 14 ] and internal peak fittings [ 15 ], as further depicted in FIGS. 5A , 5 B, 5 C, 5 D, a plurality of box frame support members [ 30 ], and a plurality of tubes [ 18 ] securely attaching the end peak fittings [ 14 ] and the internal peak fittings [ 15 ] to the box frame support members [ 30 ].
The plurality of peak fittings [ 14 and 15 ] are positioned on the gable assembly, the peak fittings being connected by at least one peak fitting connector tube [ 17 ].
The plurality of box frame support members [ 30 ] are preferably two parallel members, although other configurations are also envisioned. Preferably, the box frame support members [ 30 ] are essentially parallel to the peak fitting connector tube [ 17 ]. The peak fittings [ 14 and 15 ], the peak fitting connector tube [ 17 ], tubes [ 18 ], and additional connectors and fasteners (not shown) can be stored inside the plurality of box frame support members [ 30 ] prior to assembly and during shipping.
Tubes [ 18 ] are used as needed to attach the peak fitting connector tube [ 17 ] to the box frame support members [ 30 ] and to lay a foundation for the canopy [ 16 ]. The tubes [ 18 ] securely attach the peak fittings [ 14 and 15 ] and the peak fitting connector tube [ 17 ] to the box frame support members [ 30 ].
The canopy [ 16 ] covers the gable assembly [ 13 ] protecting the watercraft from the sun and rain. The canopy [ 16 ] is securely affixed to the gable assembly [ 13 ]. The canopy [ 16 ] can be of any fabric type material which has sufficient wind- and ultraviolet- (UV) resistant properties, with the preferred embodiment being vinyl for its durability and ease of maintenance.
The adjustable support structure [ 20 ] enables elevation and lowering of portions of the gable assembly [ 13 ] of the modular boat lift cover of the present invention [ 10 ]. The adjustable support structure [ 20 ] is compatible with a wide variety of modular boat lift covers, and can be mounted on any type of boat lift.
For larger watercraft a longer gable assembly [ 13 ] is required, and additional ballast is needed. The modular boat lift cover [ 10 ] includes a pair of centered brackets [ 32 ], one secured to each box frame [ 30 ] with an upper bracket [ 33 ] and secured to the deck assembly [ 12 ] with a variable centered bracket [ 34 ]. The upper bracket [ 33 ] for the centered bracket [ 32 ] is depicted in FIGS. 9A , 9 B and 9 C. The variable centered bracket [ 34 ] for the centered bracket [ 32 ] is depicted in FIGS. 10A , 10 B and 10 C.
FIG. 2A depicts an assembly end view of a preferred embodiment of a gable assembly [ 13 ] for the modular boat lift cover of the present invention [ 10 ]. FIG. 2B depicts a preferred embodiment of an end view of the gable assembly [ 13 ] of FIG. 2A mounted on an adjustable support structure [ 20 ]. The gable assembly [ 13 ] is supported upon the adjustable support structure [ 20 ] which includes a plurality of beam brackets [ 25 ] and a plurality of support columns [ 28 ], each support column [ 28 ] being disposed within a beam bracket [ 25 ]. The adjustable support structure [ 20 ] provides a vertical adjustment for portions or all of the gable assembly [ 13 ]. The adjustable support structure [ 20 ] enables the bow section of the gable assembly [ 13 ] to be raised or lowered, the stern section of the gable assembly [ 13 ] to be raised or lowered, or their combination to be raised or lowered. Similarly, the port and starboard sections of the gable assembly [ 13 ] can be raised or lowered. The preferred angle between the tubes [ 18 ] of the gable assembly [ 13 ] is 150°.
FIG. 2C depicts a preferred embodiment of an end view of the gable assembly [ 13 ] of FIG. 2A mounted on a pair of centered brackets [ 32 ] and variable centered brackets [ 34 ]. The centered brackets [ 32 ] are secured to the box frame support members [ 30 ] by a pair of upper brackets [ 33 ].
FIG. 2D depicts an exploded view of a preferred embodiment of an end view of the gable assembly [ 13 ] and adjustable support structure [ 20 ] of FIG. 2B . Tubes [ 18 ] are inserted into the end peak fitting [ 14 ] and pipe fittings [ 37 ], which are in turn attached to the box frame support members [ 30 ]. The box frame support members [ 30 ] are fastened to the support columns [ 28 ] with U-bolts [ 45 ]. Each support column [ 28 ] is disposed within a beam bracket [ 25 ] and held in place with a clevis pin [ 29 ]. The clevis pin [ 29 ] can be removed to enable vertical adjustment of the support column [ 28 ] within the beam bracket [ 25 ]. The beam brackets [ 25 ] are in turn fastened to I-beams [ 44 ] of the deck assembly [ 12 ] using bolts [ 41 ] and beam clamps [ 42 ].
FIG. 3 depicts a preferred embodiment of an assembly side view of a curved gable assembly [ 70 ] of the modular boat lift cover of the present invention [ 10 ].
The curved gable assembly [ 70 ] includes a plurality of end peak fittings [ 14 ] and internal peak fittings [ 15 ], as further depicted in FIGS. 5A , 5 B, 5 C, 5 D, a plurality of box frame support members [ 30 ], and a plurality of bowed tubes [ 62 ] that are initially linear in shape but become bowed under stress are securely attaching the end peak fittings [ 14 ] and the internal peak fittings [ 15 ] to the box frame support members [ 30 ].
The plurality of peak fittings [ 14 and 15 ] are positioned on the curved gable assembly [ 70 ], the peak fittings being connected by at least one peak fitting connector tube [ 17 ].
The plurality of box frame support members [ 30 ] are preferably two parallel members, although other configurations are also envisioned. Preferably, the box frame support members [ 30 ] are essentially parallel to the peak fitting connector tube [ 17 ]. The peak fittings [ 14 and 15 ], the peak fitting connector tube [ 17 ], bowed tubes [ 62 ], and additional connectors and fasteners (not shown) can be stored inside the plurality of box frame support members [ 30 ] during shipping.
The bowed tubes [ 62 ] are used as needed to attach the peak fitting connector tube [ 17 ] to the box frame support members [ 30 ] and to lay a foundation for the canopy [ 16 ]. The bowed tubes [ 62 ] securely attach the peak fittings [ 14 and 15 ] and the peak fitting connector tube [ 17 ] to the box frame support members [ 30 ] using pipes [ 60 ] attached to the box frame support members [ 30 ].
An advantage of the curved gable assembly [ 70 ] is that it enables the creation of a canopy overhang on either side of the modular boat lift cover of the present invention [ 10 ]. This enables additional protection of the watercraft from sun and rain and provides additional support during storms and high winds.
The canopy overhang comprises a canopy anchor support bar [ 58 ] which is preferably parallel to the box frame support members [ 30 ] and the peak fitting connector tube [ 17 ]. The canopy anchor support bar is connected to the box frame support member [ 30 ] using a plurality of end canopy overhang fittings [ 55 ] and internal canopy overhang fittings [ 56 ], which are further depicted in FIGS. 5E and 5F .
The canopy overhang can be adjusted to suit the user's needs. For example, if the modular boat lift cover of the present invention [ 10 ] is installed in an east-west orientation, there will be more exposure to the sun throughout the day on the southern side of the watercraft. The canopy overhang can be installed such that the side facing south is longer, thus providing more protection from the sun.
FIGS. 4A , 4 B and 4 C depict an assembly end view of a preferred embodiment of a curved gable assembly [ 70 ] for the modular boat lift cover of the present invention [ 10 ], similar to FIGS. 2A , 2 B and 2 C, with the bowed tubes [ 62 ].
FIG. 4D depicts an exploded view of a preferred embodiment of an end view of the curved gable assembly [ 70 ] and adjustable support structure [ 20 ] of FIG. 4B . The tubes [ 62 ] are inserted into the end peak fitting [ 14 ] and pipes [ 60 ], which are in turn attached to the box frame support members [ 30 ]. The box frame support members [ 30 ] are fastened to the support columns [ 28 ] with U-bolts [ 45 ]. Each support column [ 28 ] is disposed within a beam bracket [ 25 ] and held in place with a clevis pin [ 29 ]. The clevis pin [ 29 ] can be removed to enable vertical adjustment of the support column [ 28 ] within the beam bracket [ 25 ]. The beam brackets [ 25 ] are in turn fastened to I-beams [ 44 ] of the deck assembly [ 12 ] using bolts [ 41 ] and beam clamps [ 42 ].
FIG. 6A depicts the box frame support member [ 30 ] as well as pipe fittings [ 37 ] and the upper bracket [ 33 ]. FIG. 6B depicts an end view of the box frame support member [ 30 ] with the attached pipe fitting [ 37 ] and tube [ 18 ], which forms part of the gable assembly [ 13 ]. FIG. 6C depicts a side view of the box frame support member [ 30 ] with the attached pipe fitting [ 37 ]. FIG. 6D depicts an isometric view of two box frame support members [ 30 ] and a splice reinforcement [ 52 ], which is used for connecting the box frame support members [ 30 ] and strengthening the connection juncture. This enables the user to vary the length of the modular boat lift cover of the present invention [ 10 ]. For smaller watercraft, the box frames [ 30 ] will not need to be spliced together in the gable assemblies, but rather a single box frame [ 30 ] on each side of the gable assemble will suffice. Only for larger watercraft, will multiple modular gable assemblies be needed, and the splice reinforcements [ 52 ] are needed to strengthen these junctures.
The preferred embodiment of the beam bracket [ 25 ] of the modular boat lift cover of the present invention [ 10 ] is depicted in FIGS. 7A , 7 B, and 7 C. Holes [ 27 ] for the insertion of a clevis pin [ 29 ] are shown. The bottom plate is adjustable as after said bottom plate is secured to the beam bracket [ 25 ] excess may be cut off after mounting. The beam bracket [ 25 ] can be rotated 180°, on one side or both sides of the lift cover to enable for boat accessories such as outriggers or just to give additional protection from sunlight and rain.
In one preferred embodiment, the modular boat lift cover of the present invention [ 10 ] features a top drive shaft used to raise and lower the boat. Box risers (not shown) may be used to provide raised attachment points for the beam brackets [ 25 ]. A box lift riser is attached to the boat lift frame on both sides of the drive shaft along the longitudinal axis. This enables normal functioning of the drive shaft with no interference from the beam brackets [ 25 ].
The preferred embodiment of the support column [ 28 ] is depicted in FIGS. 8A , 8 B, and 8 C. The support column [ 28 ] is a bit smaller than the beam bracket [ 25 ] and fits inside the beam bracket [ 25 ]. A clevis pin [ 29 ] as shown in FIGS. 2D and 4D enables the relative height of the support column relative to the beam bracket [ 25 ] to be adjusted. Holes for the insertion of a clevis pin [ 29 ] are shown.
FIG. 11 depicts a plurality of tubes [ 18 ] packaged inside a box frame support member [ 30 ] of the gable assembly [ 13 ] for the modular boat lift cover of the present invention [ 10 ]. This packaging method enables for ease of shipping, and ensures no parts are missing.
FIG. 12 depicts an isometric view of a preferred embodiment of the box frame end cap [ 49 ] and box frame support member [ 30 ] of the modular boat lift cover of the present invention [ 10 ]. The box frame end cap [ 49 ] fits securely into the box frame support member [ 30 ]. During shipping, this prevents the other components of the modular boat lift cover [ 10 ] from falling out. Once the modular boat lift cover [ 10 ] is installed by the user, the box frame end cap [ 49 ] prevents debris and other material from entering the channel of the box frame support member [ 30 ].
FIG. 13A depicts one preferred embodiment for attaching the canopy [ 16 ] to the gable assembly [ 13 ] of the modular boat lift cover of the present invention [ 10 ]. Knobs [ 47 ] and elastic cords [ 48 ] are used to secure the canopy [ 16 ] in place. In a second preferred embodiment of the modular boat lift cover of the present invention, the canopy [ 16 ] is sold separately and is not included in the assembly.
FIG. 13B depicts another view of a preferred embodiment for attaching the canopy [ 16 ] to the curved gable assembly [ 70 ] of the modular boat lift cover of the present invention [ 10 ]. The canopy [ 16 ] is stretched over the curved tubes [ 62 ] which are inserted into the pipes [ 60 ]. The pipes [ 60 ] are attached to the box frame support member [ 30 ]. Knobs [ 47 ] and elastic cords [ 48 ] are used to secure the canopy [ 16 ] in place. The elastic cords [ 48 ] are attached to the canopy anchor support bar [ 58 ].
The modular boat lift cover of the present invention [ 10 ] will be used on any boat lift and will replace the complicated current manufacturing process, complicated design, costly training of the sales force and installation teams, and will be stronger and last longer for the customer. This new design is a boat lift cover or canopy that is adjustable for width, height, length and placement on almost any boat lift.
The modular boat lift cover of the present invention [ 10 ], preferably includes two 3 inch×6 inch aluminum box frame support members [ 30 ] with stainless steel connection bolts covered with a unique vinyl cover. This design has many fewer parts than current designs and will establish a new standard of strength and flexible and scalable design at a much lower cost. Significant cost savings will also be achieved with the tubes [ 18 ] fitting into the 3 inch×6 inch box frame support members [ 30 ]. In addition, customers will see a significant reduction in installation and service costs. This is only possible because of the simplicity in design and packaging. Also, there is a box frame end cap [ 49 ] which is included which covers the open end of the box frame support members [ 30 ] in order to prevent birds and other animals from taking up residence in the box frame support members [ 30 ].
Some of the many novel features of the modular boat lift cover of the present invention [ 10 ] include that the modular boat lift cover [ 10 ] is compatible with and will mount or fit on almost any boat lift, it is adjustable for the width, height and length of most any watercraft. Also, the tubes [ 18 ] and multiple gable components will fit into the box frame support members [ 30 ] for high density packaging, protecting the gable assembly [ 13 ] components, insuring that the kit is complete (no parts are missing), ease of assembly and significant cost savings both in the manufacturing process as well as the installation process. The modular boat lift cover of the present invention [ 10 ] is also designed to survive wind speeds of greater than 150 miles per hour, or those found in a Category 5 hurricane. However, the vinyl cover must be and is easily removable by the modular boat lift cover [ 10 ] owner in event of a hurricane or other high winds.
Also, the modular boat lift cover [ 10 ] is designed to withstand winds of up to 180 miles per hour. The structural framing members have been designed in accordance with Florida Building Code Section 3105—Awnings and Canopies—specifically Section 3105.4.2.1 parts 1, 2 and 3, based on a rational analysis using Category 1 hurricane winds and exposure “D” corrosion. The design condition basis is a minimum wind gust velocity of 116 miles per hour (for 3 seconds) when the cover has been removed, and an ultimate sustained wind speed of 150 miles per hour. In the event of a hurricane, the owner will be able to quickly and easily remove the canopy [ 16 ].
All of the components of the gable assembly [ 13 ] will fit into the channel of one of the 3″×6″ aluminum box frame support members [ 30 ], thereby improving quality control and packaging for the manufacturer, as well as giving the customer peace of mind knowing that everything will be in place without having multiple packages to deal with.
The preferred embodiment of the modular boat lift cover of the present invention [ 10 ] uses aluminum construction in all materials to make the apparatus lighter and easier to use as well as corrosion resistant. However, other lightweight materials may also be used that are corrosion resistant and provide the unit with the necessary strength.
Accordingly, it will thus be seen from the foregoing description that the modular boat lift cover of the present invention [ 10 ] along with the accompanying drawings provides a new and useful modular gable assembly that is expandable and readily modifiable to adapt to changes in the watercraft. In addition, the modular boat lift cover of the present invention [ 10 ] can be deployed with a different watercraft having desired advantages and characteristics, enabling the owner of the watercraft to deploy the modular boat lift cover of the present invention [ 10 ] as a building block to accommodate other watercraft that he or she may subsequently acquire.
Throughout this application, various Patents and Applications are referenced by number and inventor. The disclosures of these documents in their entireties are hereby incorporated by reference into this specification in order to more fully describe the state of the art to which this invention pertains.
It is evident that many alternatives, modifications, and variations of the adjustable modular boat lift cover of the present invention will be apparent to those skilled in the art in light of the disclosure herein. For example, the system can be used for all types of boat lifts as well as other applications, such as a portable event tent. It is intended that the metes and bounds of the present invention be determined by the appended claims rather than by the language of the above specification, and that all such alternatives, modifications, and variations which form a conjointly cooperative equivalent are intended to be included within the spirit and scope of these claims.
PARTS LIST
10 . Modular Boat Lift Cover
12 . Deck Assembly
13 . Gable Assembly
14 . End Peak Fitting
15 . Internal Peak Fitting
16 . Canopy
17 . Peak Fitting Connector Tube
18 . Tube
20 . Adjustable Support Structure
25 . Beam Bracket
27 . Fastener Hole
28 . Support Column
29 . Clevis Pin
30 . Box Frame Support Member
32 . Centered Bracket
33 . Upper Bracket
34 . Variable Centered Bracket
37 . Pipe Fitting
41 . Bolt
42 . Beam Clamp
44 . I-Beam
45 . U-Bolt
47 . Knob
48 . Elastic Cords
49 . Box Frame End Cap
50 . Piling
52 . Splice
55 . End Canopy Overhang Fitting
56 . Internal Canopy Overhang Fitting
58 . Canopy Anchor Support Bar
60 . Pipe
62 . Bowed Tube
70 . Curved Gable Assembly | The modular boat lift cover for a watercraft has a gable assembly. All of the straight components of the gable assembly are packaged into the main box frame channel for simplicity in packaging as well as quality control, ensuring no components are missing during packaging and shipping. The modular boat lift cover has a robust, lightweight design that is compatible and adjustable for width, height and length as the boat owner modifies his existing boat or purchases a new boat of different dimensions that will protect the watercraft from the elements and is designed to withstand even the severest of storms, undamaged. The modular boat lift cover is easy for the user to assemble and adjust on square lake style boat lifts, as well as the typically non-square tidal lifts. | 4 |
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application is the U.S. national stage of International Application No. PCT/EP2010/061931, filed Aug. 17, 2010 and claims the benefit thereof. The International Application claims the benefit of German Application No. 10 2009 047 801.9 filed on Sep. 30, 2009; both applications are incorporated by reference herein in their entirety.
BACKGROUND
[0002] Described below is a flow chamber of a flow cytometer, in which labeled cells may be detected with a high level of probability with the assistance of an appropriate sensor.
[0003] In a magnetic flow cytometer, labeled cells which are to be detected with the assistance of appropriate sensors must be conveyed close above the surface of a sensor in a flow chamber. For example, GMR (giant magnetoresistance) sensors or optical fluorescence or scattered light sensors are used for this purpose. The cell must be close to the sensor, since for example in the case of a GMR sensor the magnetic scatter field of the magnetic labels, which is ultimately utilized by the GMR sensor for detection, declines with the cube of distance from the sensor. The same applies to optical measurement methods.
[0004] In order to ensure that a labeled cell passes by in the immediate vicinity of the sensor, it is in principle conceivable to make the diameter of the channel through which the medium carrying labeled cells flows as small as possible, i.e. in an extreme case the diameter of the channel is just big enough for individual cells to be able to pass through. The drawback of this approach is of course that the presence of impurities or disruptive particles very rapidly results in the channel being blocked. On the other hand, if the channel is made larger, there is also a greater probability that individual labeled cells will pass by outside the range of the sensor and will thus not be detected. This drawback may be countered by providing a larger number of sensors, but this entails more complex electronics.
SUMMARY
[0005] Described below is a flow chamber in which there is an elevated probability of detecting a labeled cell with a sensor of the flow chamber. Through the flow chamber in a flow cytometer flows a medium carrying magnetically labeled cells. The flow chamber has at least one sensor for cell detection positioned on an internal surface of the flow chamber, and is equipped with a magnetic or magnetizable cell-guiding device. The latter is positioned upstream of the sensor in the direction of flow and arranged and constructed there such that it guides the flowing, magnetically labeled cells over the sensor.
[0006] The cell-guiding device is advantageously arranged on the internal surface of the flow chamber and includes a number n, with n≧1, of magnetic or magnetizable flow strips oriented substantially parallel to the direction of flow, wherein
the number n of flow strips corresponds to the number of sensors, one flow strip is in each case assigned to one sensor and a magnetically labeled cell guided by a flow strip is guided over the assigned sensor.
[0010] In a first embodiment, a flow strip is of a width which remains constant throughout in the direction of flow.
[0011] In a second embodiment, a flow strip tapers in the direction of flow, in particular in the manner of a funnel or half funnel.
[0012] In a third embodiment, an individual, wide flow strip divides, in the direction of flow, into a plurality of narrower, substantially parallel flow sub-strips, wherein the number of flow sub-strips corresponds to the number of sensors.
[0013] In a fourth embodiment, the flow strips are arranged in a herringbone pattern.
[0014] In an advantageous embodiment, part of a flow strip, in particular the downstream part in the direction of flow, is subdivided into a plurality of portions lying downstream of one another and spaced apart from one another.
[0015] In an advantageous embodiment, a magnet is provided which is arranged in such a manner on the flow chamber that a force directed towards the internal surface is generated which acts on the magnetically labeled cells.
[0016] In a further advantageous embodiment, the sensor is a GMR sensor.
[0017] In a further embodiment, a further magnetic or magnetizable cell-guiding device is provided which is positioned downstream of the sensor in the direction of flow.
[0018] In the method, magnetically labeled cells in a medium flowing through a flow chamber of a flow cytometer are detected with a sensor by guiding the flowing, labeled cells over the sensor with a magnetic or magnetizable cell-guiding device, which is positioned upstream of the sensor in the direction of flow.
[0019] In an advantageous further embodiment of the method, a further cell-guiding device is used, which is arranged downstream of the sensor in the direction of flow. The medium is guided over the sensor alternately in a first direction and in a second direction, which is contrary to the first direction.
BRIEF DESCRIPTION OF THE DRAWINGS
[0020] These and other aspects and advantages will become more apparent and more readily appreciated from the exemplary embodiments described below with reference to the accompanying drawings of which:
[0021] FIG. 1 is a cross-section of a flow chamber,
[0022] FIG. 2 is a plan view of a first embodiment of the cell-guiding device,
[0023] FIG. 3 is a plan view of a second embodiment of the cell-guiding device,
[0024] FIG. 4 is a plan view of a third embodiment of the cell-guiding device,
[0025] FIG. 5 is a plan view of a fourth embodiment of the cell-guiding device,
[0026] FIG. 6 is a plan view of a fifth embodiment of the cell-guiding device,
[0027] FIG. 7 is a plan view of a further embodiment of the cell-guiding device,
[0028] FIGS. 8A-8C and 8 A′- 8 C′ are plan views and side views, respectively, of three embodiments of the flow strip and
[0029] FIGS. 9A-9C are side views illustrating the principle of cell concentration.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0030] In the figures, identical or mutually corresponding zones, components, and component assemblies are designated with the same reference numerals.
[0031] FIG. 1 shows a flow chamber 10 of a flow cytometer in cross-section. A medium 70 , which contains the magnetically labeled cells 20 to be detected as well as unlabeled cells 30 , passes in the direction of flow 130 through an orifice 40 into the flow chamber 10 . The medium 70 flows through a microfluidic channel 11 of the chamber 10 and, after detection, leaves the latter through a further orifice 50 . The magnetically labeled cells 20 are detected with the aid of a sensor 60 . The sensor 60 may for example be a GMR sensor or an optical fluorescence or scattered light sensor. By way of example below, it is assumed that a GMR sensor 60 is used.
[0032] FIG. 1 likewise shows an optional permanent magnet 140 , which is located below the microfluidic channel 11 and which generates a magnetic field (not shown). This field on the one hand attracts the magnetically labeled cells 20 , so ensuring that they brush over the sensor 60 close to the surface thereof. On the other hand, the magnet 140 , especially in the case assumed here of a sensor 60 of the GMR type, may be used in order to generate the gradient field required for operation of this type of sensor; when the magnetic cells 20 pass over the GMR sensor 60 they influence the magnetic field prevailing at the location of the sensor. This is recorded by the GMR sensor and utilized for detection. Alternatively, a corresponding energized coil may of course also be used instead of the permanent magnet 140 . In the event that the sensor 60 is an optical fluorescence or scattered light sensor or the like, a magnetic field is, of course, not required for sensor operation. Nevertheless a magnet may also be provided in order, as mentioned, to ensure that the labeled cells 20 pass close over the surface of the sensor 60 .
[0033] When dimensioning the magnet 140 , care must be taken to ensure that the strength of the magnetic field is matched to the flow velocity of the medium. If the magnetic field and thus the retention force is too strong, disruption to flow cannot be ruled out as individual cells 20 may possibly be immobilized. Conversely, if the magnetic field is too weak, it is to be assumed that some of the labeled cells 20 will pass by the sensor 60 outside the range thereof, i.e. that they will not be detected.
[0034] By way of the interplay between the strength of the magnetic field of the magnets 140 and the flow 130 , generated for example by pumps (not shown), or the velocity thereof, it is possible purposefully to adjust the retention force for magnetically labeled cells 20 in order, on the one hand, to remove cells with low labeling density, i.e. “false positive” cells, and, on the other hand, only to convey cells with sufficiently strong immunomagnetic labeling to the sensor 60 , with any unbound labels, for example superparamagnetic particles, not being conveyed to the sensor due to the lower retention force.
[0035] In a concentration device not shown in FIG. 1 , which is described in greater detail in FIG. 8 , the medium 70 may initially be concentrated before the actual detection, i.e. the concentrated medium 70 leaving the concentration device would enter the flow chamber 10 via the orifice 40 .
[0036] The flow chamber 10 includes a cell-guiding device 120 . This device 120 ensures that the magnetically labeled cells 20 which are still stochastically distributed at the inlet 40 to the flow chamber 10 , (cf. FIGS. 2 to 6 ) can be purposefully guided over the sensor 60 . This has the advantageous consequence that a substantially larger number of cells 20 may be detected, since distinctly fewer cells flow past, for example to the side of, the sensor 60 . It is accordingly no longer left to chance whether a labeled cell 20 comes within the range of the sensor 60 and is detectable.
[0037] To this end, magnetic or magnetizable metal tracks are arranged in the direction of flow on or in that internal surface 12 of the flow chamber 10 on which the sensor 60 is also arranged. As is explained below with reference to the figures, these metal tracks or “flow strips” may for example be of constant width, taper in the manner of a funnel or half funnel, converge in a fan shape or also be arranged in a herringbone pattern. Others arrangements which likewise ensure that the labeled cells 20 are guided over the sensor 60 are, of course, likewise conceivable. The flow strips may furthermore be of continuous or alternatively of discontinuous design. A discontinuous design (cf. FIG. 8B , 8 C) singulates the cells 20 , i.e. it is ensured that a plurality of cells 20 do not brush over the sensor 60 simultaneously or immediately one after the other. Because individual cells 20 now brush over the sensor 60 , it is ensured that individual cell analysis may be carried out more efficiently.
[0038] FIG. 2 , like FIGS. 3 , 4 , 5 and 6 , shows a plan view of the interior of a flow chamber 10 , the unlabeled cells 30 not being shown for the sake of clarity. For the same reason, only a few of the cells 20 are provided by way of example with reference numerals. In this exemplary embodiment, the cell-guiding device 120 has four flow strips 121 made of a magnetic or a magnetizable material. The flow strips 121 are arranged parallel to one another and are oriented in the direction of flow 130 of the medium. The width of the flow strips 121 may be substantially in line with the diameter of the cells 20 , but is however generally less than the width of the sensors 60 .
[0039] The interaction between the magnetic cells 20 and the magnetic flow strip 121 ensures that the cells 20 , as they flow past the strips 120 with the medium 70 , leave their stochastic distribution and arrange themselves on the strips 121 :
in a first zone I, the cells 20 are stochastically distributed. in a second zone II, the cells 20 align themselves with the flow strip 121 . in a third zone III, the cells 20 arranged on the flow strip 121 are conveyed to the sensors 60 . in a fourth zone IV, (individual) cell detection takes place.
[0044] The boundaries of zones I to IV are here not sharply defined, but are instead variable, for example, as a function of the field of the magnet 140 and the flow velocity. In other words, the zones shown in the figures should be understood as examples.
[0045] Because the magnetic gradient is steepest at the edge of the respective flow strip 121 , it is to be assumed that the cells 20 will not arrange themselves centrally on the respective flow strip 121 , but instead on the edge thereof.
[0046] In the direction of flow downstream of each flow strip 121 , i.e. as an extension of the strip 121 , there is located a sensor 60 , such that the labeled and ordered cells 20 may be purposefully guided over the sensor 60 with the assistance of the cell-guiding device 120 . Apart from a few exceptions, which were not caught by the magnetic flow strip 121 and were therefore not guided to the sensors 60 , it may be assumed that a large proportion of the labeled cells 20 in the medium 70 will come within the range of the sensors 60 , such that a substantially higher yield may be achieved with the arrangement, which is for example manifested, with constant statistics, in a shorter measurement time or, with a constant measurement time, in improved statistics.
[0047] The flow strips may for example be made of nickel and be ≦10 μm wide and 100-500 nm thick. Thicknesses of an order of magnitude of 1 μm are, however, likewise conceivable. The microfluidic channel 11 is typically 100-400 μm wide, 100 μm high and approx. 1 mm long. The GMR sensors 60 are approx. 25-30 μm long (in a direction perpendicular to the direction of flow 130 ).
[0048] FIG. 3 shows a further exemplary embodiment of a cell-guiding device 120 . In this case, the cell-guiding device 120 has only one flow strip 122 , which however tapers in the manner of a funnel in the direction of flow 130 until it is ultimately of a width which approximately corresponds to the diameter of the cells 20 . At its wide end, the strip 122 covers the entire width of the flow cell 10 or of the microfluidic channel 11 . This wide zone of the strip virtually acts as a collector with which the cells 20 may be led towards the narrow flow strip.
[0049] In this exemplary embodiment too, the flow strip 122 may be made of a magnetic or a magnetizable material, such that here too the initially stochastically distributed, magnetically labeled cells 20 may be ordered and finally guided over the sensor 60 .
[0050] The advantage of the arrangement of FIG. 3 over that of FIG. 2 is, for example, that in this case only one sensor 60 is required. This permits simplification of the readout electronics.
[0051] In a third exemplary embodiment of the cell-guiding device 120 which is shown in FIG. 4 , the latter is formed of two magnetic or magnetizable flow strips 123 , which in each case taper in the manner of a half funnel in the direction of flow 130 . As in the other exemplary embodiments, in this case too a sensor 60 is assigned to each flow strip 123 , which sensor is located in the direction of flow 130 downstream of the flow strip 123 and over which the labeled cells 20 are guided.
[0052] FIG. 5 shows a fourth exemplary embodiment. The flow strip 124 shown here is, like the examples of FIGS. 2 and 3 , of comparatively wide construction on the input side, i.e. in zone I. The single, wide flow strip 124 is, however, divided into four flow sub-strips 124 / 1 to 124 / 4 , over which the cells 20 are guided to the sensors 60 , as in the previous exemplary embodiments.
[0053] FIG. 6 shows a fifth exemplary embodiment of the cell-guiding device 120 . In this case, the flow strips 125 are arranged in a herringbone pattern, i.e. a central flow strip 125 / 1 is on the one hand provided which extends to the sensor 60 . Further flow strips 125 / 2 , 125 / 3 are on the other hand provided, which are arranged at an angle of for example ±45° to the direction of flow 130 , such that the magnetically labeled cells 20 are initially guided to the central flow strip 125 / 1 and thence over the sensor 60 .
[0054] FIG. 7 shows an embodiment which, with regard to the arrangement of the flow strips 121 , corresponds in principle to that of FIG. 2 . Unlike FIG. 2 , however, flow strips 121 , 121 ′ are in this case arranged both upstream and downstream of the sensors 60 in the direction of flow. In a corresponding detection method, the medium and thus the labeled cells 20 would be conveyed alternately in a first direction of flow 130 and in the opposite direction 130 ′, for example in order to improve the statistics. The cells 20 accordingly brush repeatedly over the sensors 60 .
[0055] In principle, the embodiment of FIG. 7 with a cell-guiding device arranged on both sides of the sensors 60 may, of course, also be constructed in accordance with the embodiments of the cell-guiding devices of FIGS. 3 to 6 . However, since the cells 20 passing over the sensor 60 are generally already ordered, i.e. no longer stochastically distributed, it is generally sufficient to construct the further cell-guiding device 120 ′ as shown in FIG. 7 . A kind of “collector”, as the cell-guiding devices 120 in particular of FIGS. 3 , 4 and 5 in zone I which primarily serve to guide the stochastically distributed cells 20 towards the individual tracks, would only be necessary in the case of the further cell-guiding device if it were possible to supply a medium to the flow chamber 10 both via the orifice 40 and via the orifice 50 .
[0056] FIGS. 8 A to 8 C′ show various embodiments of individual flow strips. The figures provide a side view and a plan view of the flow strip of each embodiment with magnetically labeled cells 20 arranged thereon.
[0057] The flow strip 126 of FIG. 8A is of continuous construction, as also shown in FIGS. 1 to 7 .
[0058] FIG. 8B , in contrast, shows discontinuous flow strip 127 . In the upstream part 127 / 1 in the direction of flow 130 , the strip is likewise of continuous construction. The downstream part 127 / 2 of the flow strip 127 is, however, discontinuous, i.e. the strip is here divided into a plurality of portions 127 / 3 arranged downstream of one another. As described above, this has an advantageous effect on the possibility of individual cell detection. The length of the individual portions 127 / 3 may for example correspond to the width of the strip and/or approximately to the diameter of the cell.
[0059] The flow strip 128 of FIG. 8C substantially corresponds to that of FIG. 8B , i.e. an upstream, continuous part 128 / 1 and a downstream, discontinuous part 128 / 2 with individual portions 128 / 3 are provided. In addition, however, a continuous strip 128 / 4 is applied onto the portions 128 / 3 , which continuous strip for example prevents cells 20 being diverted into the zones between the portions 128 / 3 by any turbulence in the flow.
[0060] FIG. 9 illustrates the principle of concentration in simplified manner. FIG. 9A here shows a plan view of the concentration device 80 , while FIGS. 9B and 9C show two side views or cross-sections of the device 80 at successive points in time t 1 , t 2 (t 2 >t 1 ). Typically, the concentration of the magnetically labeled cells 20 is comparatively low in the original medium, for example whole blood. Analysis would be very time-consuming. The original medium, which flows through a channel 100 in the concentration device 80 , is therefore concentrated before detection, the intention being to increase the proportion of labeled cells 20 in the medium relative to the proportion of unlabeled cells 30 .
[0061] FIG. 9 illustrates “semi-continuous” concentration, in which the concentration proceeds first at time t 1 (cf. FIG. 9B ) and then the concentrated medium is conveyed to the flow chamber at time t 2 ( FIG. 9C ). Further concentration (not shown) would then proceed etc.
[0062] Concentration is performed using a magnet 90 which generates a first magnetic field (not shown) of an order of magnitude of approx. 100-1000 mT. This attracts the magnetically labeled cells 20 onto the side of the channel 100 on which the magnet 90 is arranged. Accordingly, the concentration of labeled cells 20 is distinctly increased on this side of the channel 100 . It is specifically on this side that a further channel 110 is furthermore provided, via which the now concentrated medium reaches the flow chamber 10 , which is shown only symbolically in FIG. 9 . In order to keep the magnetically labeled cells 20 also in the channel 110 and finally in the flow chamber 10 on the side on which the sensor 60 is also positioned, a further magnet 91 is provided, which however generates a weaker magnetic field than the magnet 90 , for example of an order of magnitude of up to 100 mT.
[0063] The method which may be performed with the flow chamber described above is intended for use for example for mammalian cells, microorganisms or magnetic beads. Magnetic flow cytometry may be used in combination with optical (for example fluorescence, scattered light) or other non-magnetic detection methods (for example radiochemical, electrical) in order to perform in situ observations or carry out further analyses.
[0064] A description has been provided with particular reference to preferred embodiments thereof and examples, but it will be understood that variations and modifications can be effected within the spirit and scope of the claims which may include the phrase “at least one of A, B and C” as an alternative expression that means one or more of A, B and C may be used, contrary to the holding in Superguide v. DIRECTV, 358 F3d 870, 69 USPQ2d 1865 (Fed. Cir. 2004). | A flow cytometer has a flow chamber in which labeled cells are highly likely to be detected by a corresponding sensor as a medium carrying the magnetically labeled cells flows through the flow chamber. The flow chamber has at least one sensor positioned on an inner surface thereof to detect the cells. The flow chamber also has a magnetic or magnetizable cell guiding device which can be positioned upstream of the sensor in the direction of flow to guide the flowing, magnetically labeled cells directly across the sensor, so that only a small percentage of labeled cells pass outside of the reach of the sensor. | 6 |
BACKGROUND AND SUMMARY OF THE INVENTION
The present invention relates generally to heat exchangers which utilize a plurality of tubes disposed therein and, more particularly, to tube sheet support mechanisms which provide radial support to a tube sheet and transfer forces radially from the tube sheet to an outer shell structure of the heat exchanger. More specifically, the present invention relates to a radial support mechanism which transfers radial forces to the outer shell of a steam generator which comprises two coaxially associated shells.
In nuclear power generating systems, heat exchangers are used generally to transfer heat from a radioactive fluid to a non-radioactive fluid which will eventually flow through a turbine. These two fluids are isolated from each other to prevent radioactive contamination of the turbine. This heat exchanger, when utilizing water as the heat transferring medium, is referred to as a steam generator and will be referred to as such herein. Typically, a steam generator of this kind is constructed with an outer shell structure which contains both the radioactive and non-radioactive fluids, each flowing through individual separate passageways. Within this outer shell, the steam generator is compartmentalized to provide a means for providing thermal communication between these fluids without permitting them to come into physical contact with one another. This can be accomplished by passing one of the fluids through a plurality of thermally conductive tubes while causing the other fluid to flow around and in contact with the outside surfaces of these tubes.
The above-mentioned heat exchanger tubes may be U-shaped in such a way as to connect, in fluid communication, two adjacent fluid compartments located at the same end of the heat exchanger, or, alternatively, the tubes may be straight and connect, in fluid communication, compartments located at opposite ends of the heat exchanger. In either case, the fluid flowing around the outside surfaces of the heat exchanger tubes can cause lateral movement and possibly severe vibration in those tubes. In order to provide lateral support for the heat exchanger tubes, which may be of significant length, tube support plates are disposed within the steam generator. These tube support plates generally are flat circular plates with a plurality of holes through their planar surfaces. The tubes of the heat exchanger are passed through these holes with a minimal clearance so that the lateral movement of the tubes is constrained by the tube support plate. It should be understood that the tube support plate is typically designed to provide no restriction on a tube's longitudinal movement through the plate but, only to provide support which prevents lateral movement radial to the tubes which would otherwise be caused by the rapid passage of fluid over their outside cylindrical surfaces.
In steam generators which utilize a two shell construction with the tube support plates being disposed inside the inner shell, it sometimes becomes necessary to radially support the tube support plates in a way that transfers radial forces to the outer shell because of its greater strength. Even in circumstances which do not require this transfer of radial forces to the outer shell, the inner shell must usually be strengthened in some manner in order to be able to withstand radial forces exerted by the tube support plate. In this latter case, the inner shell must be locally strengthened in the region where forces from the tube support plate can be encountered.
The present invention is particularly applicable to steam generators with this type of two-shell construction. It comprises a means for exerting a force between the inner of the two shells and the tube support plate in a direction radial to the inner shell. Also, it comprises means for exerting a force between the inner and outer shells. The combination of these two means, rigidly connected to each other, transfers radial forces from the tube support plate to the outer shell and avoids potential damage to the inner shell caused by these forces. These two portions of the present invention are in threaded association with each other in a way that enables them to adjust for varying radial distances between the outer cylindrical surface of the tube support plate and the inner cylindrical surface of the outer shell. This threaded association also enables the tube support plate to be centered in relation to the inner shell during initial construction. Once assembled, the segments of the present invention can be welded to each other and also to the inner shell in such a way as to result in its rigid attachment to the inner shell.
The present invention provides a means for radially supporting a tube support plate in a steam generator while transferring radial forces from the tube support plate directly to the outer shell while avoiding potential damage to the lower strength inner shell during periods when severe radial forces on the tube support plate are experienced.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 illustrates an exemplary steam generator;
FIG. 2 depicts a former method of providing radial support to a tube support plate;
FIG. 3 shows a portion of the tube support plate mechanism of FIG. 2;
FIG. 4 illustrates the radial tube support apparatus of the present invention; and
FIG. 5 illustrates a detailed view of the force transferring apparatus of the present invention.
DESCRIPTION OF THE PREFERRED EMBODIMENT
The present invention relates generally to a means for radially supporting a tube support plate of a steam generator and, more particularly, to an apparatus which provides radial support for a tube support plate and transfers radial forces exerted by the tube support plate directly to an outer shell of a steam generator.
FIG. 1 illustrates an exemplary steam generator 10 which is internally divided into separate compartments. It comprises inner 12 and outer 14 shells. The outer shell 14 provides a containment for the portions of its heat exchanging equipment. The inner shell 12 serves to provide axial support for the tube support plates 16 and also provides a barrier which aids in fluid flow throughout the steam generator 10. A plurality of tubes 18 provide a conduit through which a fluid passes from an input area (designated by arrows I) to an output area (designated by arrows O). A separate fluid is circulated throughout the steam generator and around the outer cylindrical surfaces of the tubes 18. This fluid is in thermal communication with the fluid flowing inside the plurality of tubes 18 and is heated by its contact with the outer surfaces of the tubes 18. The heated fluid travels adjacent to the plurality of tubes 18 and is heated as it travels the path indicated by arrows H. This fluid exits from the steam generator in the form of steam and proceeds to a turbine of an electrical generating system, returning to the steam generator with a reduced temperature. This cooler fluid passes between the inner 12 and outer 14 shells of the steam generator (as indicated by arrows C) and is once again conveyed to a region proximate the plurality of tubes 18 to be heated again. This fluid thus exists in both the liquid L and gaseous G states within the steam generator.
In FIG. 1 and in the illustration described above, the fluid passing through the plurality of tubes 18 and indicated by arrows I and O, is radioactive after having come directly from a nuclear reactor to the steam generator. Also, it should be understood that the other fluid within the steam generator flowing around the outside surface of the tubes 18, and indicated by arrows C and H, is non-radioactive and one of the functions of the steam generator 10 is to transfer heat from the radioactive fluid to the non-radioactive fluid while keeping them segregated. It should further be understood that other designs of steam generators could pass non-radioactive water through the tubes 18 and radioactive water around the tubes 18 as an alternative to the procedure described herein. However, it should be equally understood that the present invention is applicable to either type of steam generator and is also applicable to heat exchangers which utilize straight tubes instead of the U-shaped tubes shown in FIG. 1.
The tube support plate 16 of a steam generator is typically supported in the axial direction by a plurality of blocks 19 welded to the inner shell 12. Radial support of the tube support plate must also be provided by some means (not shown in FIG. 1).
FIG. 2 illustrates one way to provide the radial support required for a tube support plate 16. This procedure, known to those skilled in the art, utilizes a specially shaped block 20 which is inserted into a hole burned radially through the inner shell 12. The block 20 is then welded 21 to the inner shell 12 to provide a rigid attachment therebetween. The block 20 is drilled and tapped with one or more radially extending holes into which threaded members 22 are disposed. The block 20 is radially aligned with the tube support plate 16 in such a way that the threaded members 22 can be extended from the block 20 toward the tube support plate 16. A jacking block 24 is then placed between the threaded members 22 and the tube support plate 16 in close proximity to the tube support plate 16. Wedges 26 are then driven between the jacking block 24 and the tube support plate 16 in order to provide positive contact therebetween. The wedges 26 are then welded to the jacking block 24 which, in turn, is welded to the threaded members 22 which have already been rigidly fixed, by welding, to the block 20. This configuration provides a rigid assembly comprising the block 20, threaded members 22, jacking block 24, and the wedges 26, all rigidly connected to the inner shell 12.
Prior to welding the components of this radial support mechanism together, their relative dimensions must be assured to result in the centering of the tube support plate 16 within the inner shell 12. It should be apparent that the use of the wedges 26 to accurately center the tube support plate 16 within the steam generator is difficult due to the fact that wedges typically are not suitable for making fine dimensional adjustments. Other disadvantages of this former method are that the thickness of the block 20, in order to provide localized strength to the inner shell 12, must extend radially outward from the inner shell 12 a significant amount. As shown in FIG. 2, this extension can interfere with the laminar flow of the cooled liquid as indicated by arrows C. Furthermore, in nuclear power generating systems it is desirable to minimize the number of individual components within the steam generator. From the above discussion it should be obvious that each radial support apparatus, as illustrated in FIG. 2, comprises many individual components, each of which may loosen during operation and provide a potential deleterious situation.
It should further be apparent that the overall cost of the above-described method is high. This cost arises from the need for burning a relatively large hole radially through the inner shell 12, forming the block 20 and positioning the tube support plate 16 accurately within the inner shell 12 by the repeated adjustment of the threaded members 22 and wedges 26. It has been found that the manufacture of the block 20, as depicted in FIG. 3, is both difficult and expensive. The block 20 is formed to provide an outer portion 32 which is arcuately shaped to fit the outer circumferential surface of the inner shell (reference numeral 12 in FIG. 2) while an inner portion 34 is shaped to fit within a hole formed radially through the inner shell 12. Both the inner 34 and outer 32 portions of this block must be accurately shaped into an arcuate configuration in order to be properly associated with the hole and the outer surface of the inner shell 12. Furthermore, the two holes 36 must be formed into the block 20 and threaded to receive their associated threaded members (reference numeral 22 in FIG. 2).
The present invention is exemplarily illustrated in FIG. 4, showing the inner 12 and outer 14 shells along with the tube support plate 16 and a block 19 which provides axial support for the tube support plate 16. The present invention comprises a jacking member 40, or jacking screw, which extends through a hole in the inner shell 12 and is in contact with the inner cylindrical surface of the outer shell 14. When thus disposed, the jacking member 40 is rigidly connected to the inner shell 12 by welding it, for example, as shown by reference numerals 41 and 42. Once rigidly fastened to the inner shell 12 while in positive contact with the outer shell 14, all radial forces experienced by the inner shell 12 in the region of the jacking member 40 will be transferred radially to the stronger outer shell 14. The jacking member 40 is provided with a central bore 44 which is shaped to receive a locking screw, or threaded member, 46. The threaded member 46 is provided with a head 47 which, for ease of adjustment, has a plurality of flat sides. It should be understood that by extending the threaded member 46 from the jacking member 40, the radial position of the head 47 can be accurately adjusted in order to radially position the tube support plate 16. Although the preferred embodiment of the present invention utilizes a threaded member 46 disposed in threaded association with the jacking member 40, it should be understood that an alternative configuration could have a rod slidably disposed within the hole 44 in the jacking member 40.
As illustrated in FIG. 4, it should be apparent to one skilled in the art that the head 47 of the threaded member 46 can easily be extended radially either inward or outward by rotating the head 47. This can be accomplished by the use of an open-ended wrench and does not require specialized tooling. It should further be apparent that, depending on the pitch of the threads of the threaded member 46, the head 47 can be positioned radially within the steam generator to an accurate degree. When the tube support plate 16 exerts a radially outward force, it should further be apparent that this force is transferred directly to the outer shell 14 without serious deflection to the inner shell 12. This direct transfer of force eliminates the need for the inner shell to be significantly strengthed in the region of the tube support plate 16. This apparatus also minimizes the total number of individual components required to be included within the steam generator.
By comparing the former method as shown in FIG. 2 to the present invention as illustrated in FIG. 4, the advantages of the present invention should be clearly apparent. The total number of components of the present invention comprise only the jacking member 40 and the threaded locking screw 46 whereas the former method utilized a block 20, threaded members 22, a jacking block 24 and a wedge 26. Also, the cost of manufacturing the apparatus of the present invention is significantly lower than that of the former. As explained above, the complex shape of the block 20 as illustrated in FIG. 3 is difficult, and therefore expensive, to manufacture whereas the jacking block 40 and locking screw 46, depicted in FIG. 5, are relatively easy to manufacture on conventional machinery.
FIG. 5 shows the jacking member 40 and locking screw 46 in greater detail. The jacking member 40 comprises a first end 50 which is shaped to fit against the inner cylindrical surface of the outer shell (reference numeral 14 in FIGS. 1 and 4) while its other end is provided with a means for turning it within the hole of the inner shell 12. In FIG. 5 this means is shown as a pair of holes 52 into which a spanner wrench may be fitted to provide sufficient torque to rotate the jacking member 40 within a threaded hole which extends radially through the inner shell (reference numeral 12 in FIG. 4). The outer cylindrical surface of the jacking member 40 can be thus provided with a threaded portion 48 in order that it can be threadably associated in the above-mentioned hole in the inner shell. The jacking member 40 is also provided with a central hole 44, which can also be threaded in order for it to receive, in threaded association, the locking screw 46, or threaded member. As discussed above, the locking screw 46 is provided with a head 47 which has a plurality of flat sides that enable it to be turned by the use of a conventional open-ended wrench.
After the locking screw 46 is adjusted within the jacking member 40 in order to properly position the tube support plate (reference numeral 16 in FIG. 4), the locking screw 46 can be welded to the jacking member 40 in order to rigidly attach these members together and to guarantee that no relative movement between these members occurs after installation. This welded connection is illustrated by reference numeral 49 in FIG. 4.
It should be apparent to one skilled in the art that the present invention is an apparatus which is relatively easy and inexpensive to manufacture but, that provides a radial support for a tube support plate in a way that can accurately adjust the position of the tube support plate within the steam generator. Furthermore, the present invention provides a means for effectively transferring radial forces exerted by the tube support plate to the outer shell of the steam generator without requiring the inner shell of the steam generator to be significantly strengthened in the region of the tube support plate. Also, it should be apparent that the present invention minimizes the number of components needed to be included within the steam generator in order to provide this radial support and also minimizes the deleterious effect on the fluid flow around the radial support apparatus of the present invention. | Radial support of a tube support plate is provided by two associated members which also permit the position of the tube support plate to be adjusted with significantly improved ease. The apparatus comprises a jacking member which extends radially through the heat exchanger's inner shell and is in positive contact with its outer shell. A locking screw extends radially inward from the jacking screw and is in contact with the tube support plate. After this apparatus is used to centrally locate the tube support plate, it is welded together and to the inner shell. | 5 |
FIELD OF THE INVENTION
[0001] The present invention relates to a hot work tool steel with very high thermal conductivity and low notch sensitivity conferring an outstanding resistance to thermal fatigue and thermal shock. The steel also presents a very high through-hardenability.
SUMMARY
[0002] Hot work tool steels employed for many manufacturing processes are often subjected to high thermo-mechanical loads. These loads often lead to thermal shock or thermal fatigue. For most of these tooling the main failure mechanisms comprise thermal fatigue and/or thermal shock, often in combination with some other degradation mechanisms like mechanical fatigue, wear (abrasive, adhesive, erosive or even cavitative), fracture, sinking or other means of plastic deformation, to mention the most relevant. In many other applications besides the above referred tools, materials are employed that also require high resistance to thermal fatigue often in combination with resistance to other failure mechanisms.
[0003] Thermal shock and thermal fatigue are originated by thermal gradients, in many applications where stationary transmission regimes are not attained, often due to small exposure times or limited energy amount of the source leading to a temperature decay, the magnitude of the thermal gradient in the tool material is also a function of its thermal conductivity (inverse proportionality applies for all cases with small enough Biot number).
[0004] In such scenario, for a given application with a given heat flux density function, a material with a higher thermal conductivity suffers a lower surface loading, since the resulting thermal gradient is lower.
[0005] Traditionally for many applications where thermal fatigue is the main failure mechanism, like in many instances of high pressure die casting, the measurement of toughness most widely used to evaluate different tool materials is the V-shape notched specimen resilience test (CVN—Charpy V-notch). Other measures can also be used, and are even more representative for some applications, like fracture toughness or yield deformation, deformation at fracture . . . . This measurements together with mechanical resistance related measurements (like yield stress, mechanical resistance or fatigue limit), wear related measurements (normally K-weight loss in some tribometric test) can be used as indicators of material performance for comparative purposes amongst different tool material candidates.
[0006] Therefore a merit number to compare the theoretical resistance of different materials for a given application can be:
[0000] Me·Nr =CVN≠ k /( E ·α)
Where:
CVN—Charpy V-notched
[0007] k—Thermal conductivity
—Elastic modulus
α—Thermal expansion coefficient
[0008] In most scientific literature the CVN term would be replaced by K IC , mechanical fatigue resistance, or yield strength at working temperature. But the above presented example of Merit number, is arguably one of the most intuitive amongst industrial specialists.
[0009] It is then clear that to improve thermal fatigue resistance, attempts should be made to simultaneously increase thermal conductivity, toughness and decrease elastic modulus and thermal expansion coefficient.
[0010] For many applications, thick tools are used, and thus if sufficient mechanical resistance is required as to entail heat treatment, then great trough hardenability is also desirable. Hardenability is also very interesting for hot work tool steels because it is much easier to attain a higher toughness with a tempered martensite microstructure than with a tempered bainite microstructure. Thus with higher hardenability less severity in the hardening cooling is required. Severe cooling is more difficult and thus costly to attain and since the shapes of the tools and components constructed are often intricate, it can lead to cracking of the heat treated parts.
[0011] Wear resistance and mechanical resistance are often inversely proportional to toughness. So attaining a simultaneous increase in wear resistance and resistance to thermal fatigue is not trivial. Thermal conductivity helps in this respect, by allowing to severely increase resistance to thermal fatigue, even if CVN is somewhat lowered to increase wear or mechanical resistances.
[0012] There are many other properties which are desirable, if not required, for a hot work tool steel which not necessarily have an influence on the tool or component longevity but on its production costs, like: ease of machining, weldability or reparability in general, support provided to coating, cost, . . .
[0013] In the present invention a family of tool materials with improved resistance to thermal fatigue and thermal shock, which can be combined with better resistance to mechanical collapse or wear, have been developed. Those steels also present an improved trough hardenability and CVN with respect to other existing high mechanical characteristic with high thermal conductivity tool steels (WO/2008/017341).
[0014] The authors have found that the problem of attaining simultaneously a high thermal conductivity, trough hardenability, toughness and mechanical characteristics, can be solved by applying certain compositional rules and thermo-mechanical treatments within the following compositional range:
[0000] % Ceq = 0.20-1.2 % C = 0.20-1.2 % N = 0-1 % B = 0-1 % Cr < 1.5 % Ni = 1.0-9 % Si < 0.4 % Mn = 0-3 % Al = 0-2.5 % Mo = 0-10 % W = 0-15 % Ti = 0-3 % Ta = 0-3 % Zr = 0-3 % Hf = 0-3, % V = 0-4 % Nb = 0-3 % Cu = 0-4 % Co = 0-6, % S = 0-1 % Se = 0-1 % Te = 0-1 % Bi = 0-1 % As = 0-1 % Sb = 0-1 % Ca = 0-1,
the rest consisting of iron and unavoidable impurities, wherein
[0000] % C eq =% C+0.86*%N+1.2*% B,
[0000] characterized in that
[0000] % Mo+½·% W>1.2
[0015] The more restrictive one can be with the % Si and % Cr the better the thermal conductivity but the more expensive the solution becomes (also some properties, that might be relevant for certain applications, and thus it is desired to maintain them for those applications, might deprave with the reduction of those elements under certain levels like is for example the toughness due to trapped oxide inclusions if too low Al, Ti, Si (and any other deoxidizer) are used, or certain instances of corrosion resistance if % Cr or % Si are too low) and thus a compromise is often attained between the cost increase, reduction of toughness, corrosion resistance or other characteristics relevant for certain applications, and the benefit of a higher thermal conductivity. The highest thermal conductivity can only be attained when the levels of % Si and % Cr lie below 0.1% and even better if the lay below 0.05%. Also the levels of all other elements besides % C, % Mo, % W, % Mn and % Ni need to be as low as possible (less than 0.05 is technologically possible with a cost assumable for most applications, of course less than 0.1 is less expensive to attain). For several applications where toughness is of special relevance, less restrictive levels of % Si (is the less detrimental to thermal conductivity of all iron deoxidizing elements) have to be adopted, and thus some thermal conductivity renounced upon, in order to assure that the level of inclusions is not too high. Depending on the levels of % C, % Mo, and % W used, trough hardenability might be enough, especially in the perlitic zone. To increase trough hardenability in the Bainitic zone, Ni is the best element to be employed (the amount required is also a function, besides the aforementioned, of the level of certain other alloying elements like % Cr, % Mn, . . . ). . The levels of % Mo, % W and % C used to attain the desired mechanical properties, have to be balanced with each other to attain high thermal conductivity, so that as little as possible of these elements remain in solid solution in the matrix. Same applies with all other carbide builders that could be used to attain certain tribological response (like % V, % Zr, % Hf, % Ta, . . . ).
[0016] In the whole document the term carbides refers to both primary and secondary carbides.
[0017] In general, it is convenient to attain high thermal conductivity to adhere to the following alloying rule (to minimize the % C in solid solution), if a tempered martensite or tempered bainite microstructure is desirable for the mechanical solicitations to be withstood. The formula has to be corrected if strong carbide builders (like Hf, Zr or Ta, and even Nb are used):
[0000] 0.03< x C eq−A C·[ x Mo/(3· A Mo)+ x W/(3· A W)+ x V/ A V]>0.165
[0000] where:
xCeq—Weight percent Carbon;
xMo—Weight percent Molybdenum;
xW—Weight percent Tungsten;
xV—Weight percent Vanadium;
AC—Carbon atomic mass (12,0107 u);
AMo—Molybdenum atomic mass (95,94 u);
AW—Tungsten atomic mass (183,84 u);
AV—Vanadium atomic mass (50,9415 u).
[0018] It is even more desirable, for a further improved thermal conductivity to have:
[0000] 0.05< x C eq−A C·[ x Mo/(3· A Mo)+ x W/(3· A W)+ x V/ A V]>0.158
[0000] And even better:
[0000] 0.09< x C eq−A C·[ x Mo/(3· A Mo)+ x W/(3· A W)+ x V/ A V]>0.15
[0019] To correct for the presence of other strong carbide builders, an extra term for each type of strong carbide builder has to be added in the formula:
[0000] − A C* x M/( R *AM)
Where:
[0020] xM—Weight percent carbide builder;
AC—Carbon atomic mass (12,0107 u);
R—Number of units of carbide builder per unit of carbide (p.e. 1 if carbide type is MC, 23/7 if carbide type were M 23 C 7 . . . )
AM—Carbide builder atomic mass (??? u);
[0021] This balancing provides an outstanding thermal conductivity if the ceramic strengthening particle building elements, including the non-metallic part (% C, % B, and % N) are indeed driven to the carbides (alternatively nitrides, borides or in-betweens). Thus the proper heat treatment has to be applied. This heat treatment will have an stage where most elements are brought into solution (austenization at a high enough temperature, normally above 1040° C. and often above 1080° C.), quenching will follow, the severity determined mainly by the mechanical properties desired, but stable microstructures should be avoided because they imply phases with a great amount of % C and carbide builders in solid solution. Meta-stable microstructures are even worse per se, since the distortion in the microstructure caused by carbon is even greater, and thus thermal conductivity lower, but once those meta-stable structures are relaxed is when the carbide builders find themselves in the desired placement. So tempered martensite and tempered bainite will be the sought after microstructures in this case.
[0022] In a generic way it can be said, that the higher the Mn and Si content used pursuing some specific properties, the lower the % Ni used should be, because the effect on the matrix electron thermal conductivity is too high. This can be coarsely represented by:
[0000] % Ni+9*% Mn+5*% Si<9
[0000] or even better when the upper limit can be reduced to 8% in weight.
[0023] Machinability enhancers like S, As, Te, Bi or even Pb can be used. The most common one of them, Sulphur has a comparatively low negative effect on the thermal conductivity of the matrix in the levels normally employed to enhance machinability, but it's presence has to be well balanced with the presence of Mn, to try to have all of it in the form of spherical, less detrimental to toughness, Manganese disulphide, and as little as possible of the two elements remaining in solid solution if thermal conductivity is to be maximized.
[0024] As it was mentioned before, attaining a low level of certain elements in the steels is expensive due to technological limitations. For example a steel rated as not having Cr (0% Cr in nominal composition), especially if it is an alloyed quality tool steel, will most likely have an actual % Cr >0.3%. Not mentioning % Cr, in a composition means it is not considered important, but also not its absence.
[0025] The case of % Si is a bit different, since its content can at least be reduced by the usage of refining processes like ESR, but here it is very technologically difficult, due to the small process window (and thus costly, and therefore will only be done when there's an underlying purpose) to reduce the % Si under 0.2% and simultaneously attain a low level of inclusions (specially oxides). All existing tool steel that by nominal composition range could have high thermal conductivity, do not because of the following two main reasons:
The ratio of % C and that of the carbide builders is not well balanced to minimize solid solution in the metallic matrix, especially of % C. It is often so because solid solution is intentionally employed to increase mechanical resistance. The levels of % Si and % Cr, for example, can be % Cr<1 (or even no mention to % Cr where it can be wrongly induced that it is 0%) and % Si<0.4 which means they end up being % Cr>0.3 and % Si>0.25. That also applies to all trace elements with strong incidence in matrix conductivity and even more those that have high solubility in the carbides and big structure distorting potential. In general besides % Ni, and in some instances % Mn, no other element is desired in solution within the matrix in excess of 0.5%. Preferably this quantity should not exceed 0.2%. If maximizing thermal conductivity is the main objective for a given application, then any element, other than % Ni and in some instances % C and % Mn, in solution in the matrix should not exceed 0.1% or even better 0.05%.
DETAILED DESCRIPTION OF THE INVENTION
[0028] For hot work tool steels, toughness is one of the most important characteristics, specially notch sensitivity resistance and fracture toughness. Unlike cold work applications where once enough toughness is provided to avoid cracking or chipping, extra toughness does not provide any increase in the tool life, in hot work applications where thermal fatigue is a relevant failure mechanism, tool life is directly proportional to toughness (both notch sensitivity and fracture toughness). Another important mechanical characteristic is the yield strength at the working temperature (since yield strength decreases with increasing temperature), and for some applications even creep resistance. Mechanical resistance and toughness tend to be inversely proportional, but different microstructures attain different relations, that is to say different levels of toughness can be achieved for the same yield strength at a given temperature as a function of the microstructure. In that respect it is well known that for most hot work tool steels a purely tempered martensite microstructure is the one offering the best compromise of mechanical properties. That means that it is important to avoid the formation of other microstructures like stable ferrite-perlite or metastable bainite during the cooling after austenization in the heat treatment process. Therefore fast cooling rates are going to be needed, or when even more trough hardenability is desired, some alloying elements to retard the kinetics of the formation of those more stable structures should be employed, and from all possible alternatives those with the smallest negative effect in thermal conductivity should be employed.
[0029] One strategy to provide wear resistance and higher yield strength at high temperatures while attaining a high thermal conductivity is the employment of high electron density M 3 Fe 3 C secondary and sometimes even primary carbides (M- should only be Mo or W for an improved thermal conductivity). There are some other (Mo,W,Fe) carbides with considerable high electron density and tendency to solidify with little structural defects. Some elements like Zr and to lesser extend Hf and Ta can dissolve into this carbides with lesser detrimental effect to the regularity of the structure, and thus scattering of carriers and therefore conductivity, than for example Cr and V, and they also tend to form separate MC carbides due to their high affinity for C. In general it is wished to have predominantly (Mo,W,Fe) carbides (where of course part of the % C can be replaced by % N or % B), usually more than 60% and optimally more than 80% or even 90% of such kind of carbides. Little dissolutions of other metallic elements (obviously in the case of carbides it those metallic elements will normally be transition elements) can be present in the carbides but it is desirable to limit them to guarantee a high phonon conductivity. Normally no other metallic element besides Fe, Mo and W should exceed 20% of the weight percent of the metallic elements of the carbide. Preferably it should not be more than 10% or even better 5%. This is often the case because they tend to form structures with extremely low densities of solidification defects even for high solidification kinetics (thus less structural elements to cause scattering of carriers). In this case enough impediments to the formation of stable structures (perlite and ferrite) is provided by the Mo and W, but formation of Bainite happens very fast. For some steels super-bainitic structures can be attained by applying a martempering type of heat treatment, consisting on a complete solubilisation of alloying elements and then a fast cooling to a certain temperature (to avoid the formation of ferrite) in the range of lower bainite formation, and a long holding of the temperature to attain a 100% bainitic structure. For most steels a pure martensitic structure is desired, and thus in that system some elements have to be added to retard the bainitic transformation since Mo and W are very inefficient in that respect. Normally Cr is employed for this purpose but it has an extremely negative effect in the thermal conductivity for this system since it dissolves ion the M 3 Fe 3 C carbides and causes a great distortion, so it is much better to use elements that do not dissolve into the carbides. Those elements will lower the matrix conductivity and thus those with the smallest negative effect should be employed. A natural candidate is then Ni, but some others can be employed parallely. Normally between 3% and 4% will suffice to get the desired hardenability and contribute to increase toughness without hampering conductivity excessively. For some applications less % Ni brings also the desired effects, especially if % Mn and % Si are a bit higher, or smaller sections are to be employed. So 2%-3% or even 1%-3% Ni might suffice for some applications. Finally in some applications where CVN is priorized to maximum thermal conductivity, higher % Ni contents will be employed normally up to 5,5% and exceptionally up to 9%. One further advantage of the usage of % Ni, is that it tends to lower the thermal expansion coefficient for this kind of steels at this concentration levels, with the consequent advantage for thermal fatigue (higher Merit number).
[0030] The usage of only % Mo is somewhat advantageous for thermal conductivity, but has the disadvantage of providing a higher thermal expansion coefficient, and thus lowering the overall resistance to thermal fatigue. Thus it is normally preferred to have from 1, 2 to 3 times more Mo than W, but not absence of W. An exception are the applications where only thermal conductivity is to be maximized together with toughness but not particularly resistance to thermal fatigue.
[0031] When remaining in the Mo x W 3-x Fe 3 C carbide system and keeping the levels of Cr as low as possible, one preferred way to balance the contents of % W, % Mo and % C is by adhering to the following alloying rule:
[0000] % C eq =0.3+(% Mo eq −4)·0.04173
[0000] Where: Mo eq =% Mo+½% W.
[0032] The variation allowed in the % C eq resulting from the preceeding formula, in order to optimize some mechanical or tribological property, while maintaining the desired high thermal conductivity is:
Optimally: −0.03/+0.01;
Preferably: −0.05/+0.03
Admissibly: −0.1/+0.06
[0033] This alloying rule might be reformulated in a way that better suits different % C alloys, and thus different applications:
[0000] % C eq (preliminary)=% Mo eq ·0.04173
[0000] Where: Mo eq =% Mo+½% W.
And then,
[0000] If % C eq (preliminary)<=0.3 then % C eq (final)=% C eq (preliminary)+K 1
[0000] If % C eq (preliminary)>0.3 then % C eq (final)=% C eq (preliminary)+K 2
[0000] Where K 1 and K 2 are chosen to be:
Optimally: K1 within [0.10; 0.12]; and K2 within [0.13; 0.16]
Preferably: K1 within [0.08; 0.16]; and K2 within [0.12; 0.18]
Admissibly: K1 within [0.06; 0.22]; and K2 within [0.10; 0.25]
[0034] In this case the hardenability to avoid Ferrite or perlite formation is good for % C above 0.25%. But if bainite formation is to be avoided, Ni is required in a quantity normally exceeding 3%.
[0035] Other strengthening mechanisms can be employed, searching for some specific mechanical property combination, or resistance to the degradation caused by the working environment.
[0036] Always the desired property is tried to maximize having the smallest possible negative effect on the thermal conductivity. Solid solution with Cu, Mn, Ni, Co, Si . . . (including some carbide builders with lesser carbon affinity like Cr) and interstitial solid solution (mainly C, N and B). Also precipitation can be employed for this purpose, with intermetallics formation like Ni 3 Mo, NiAl, Ni 3 Ti . . . (and thus besides Ni and Mo, the elements Al, Ti can be added in small amounts, specially Ti which does solve in the M 3 Fe 3 C carbide). And finally other types of carbides can be used, but it is normally then far more difficult to maintain a high thermal conductivity level, unless the carbide formers have a very high affinity for carbon like is the case for Hf, Zr, and even Ta. Nb and V are normally used to reduce the cost at which a certain tribological response is attained, but they have a strong incidence on thermal conductivity, so they will only be used when cost is an important factor, and in smaller quantities. Some of those elements are also not so detrimental when they solve into the M 3 Fe 3 C carbide, this is specially the case for Zr, and with lesser extend for Hf and Ta.
[0037] Whether the quantity of an element employed is big or small, when quantity is measured in weight percentiles, is a factor of the atomic mass and the type of carbide formed. To serve as an example a 2% V is much more than a 4% W. V tends to form MC type of carbides, unless it comes into solution with other existing carbides. So only one unit of V is needed to form one unit of carbide, and the atomic mass is 50.9415. W tends to form M3Fe3C type of carbides in hot work tool steels. So three units of W are needed to form one unit of carbide, and the atomic mass is 183.85. Therefore 5,4 times more units of carbide can be formed with 2% V than with 4% W.
[0038] Until the development of the High thermal conductivity tool steels (WO/2008/017341), the only means known to increase thermal conductivity of a tool steel was to keep low alloying and thus having poor mechanical characteristics, specially at high temperatures. Hot work tool steels capable of attaining more than 42 HRC after prolonged exposure to 600° C. or more, were believed to have a upper limit in thermal conductivity of 30W/mK and in thermal diffusivity of 8 mm 2 /s. The tool steels of the present invention while having those mechanical properties and a good trough hardenability present a Thermal diffusivity in excess of those 8 mm 2 /s, and in general above 11 mm 2 /s. Thermal diffusivity is chosen as the relevant thermal property because it is easier to measure with accuracy, and because most tools are applied in cyclical processes, and then thermal diffusivity is even more relevant to evaluate performance than thermal conductivity.
[0039] The tool steel of the present invention can be produced by any metallurgical route, being the most common: sand casting, fine casting, continuous casting, electric furnace melting, vacuum induction melting. Also powder metallurgy ways can be used including any kind of atomization and posterior compactation method like HIP, CIP, cold or hot pressing, sintering, thermal spraying or cladding to mention some. The alloy can be obtained directly with desired shape or further metallurgically improved. Any refining metallurgical processes might be applied like ESR, AOD, VAR . . . forging or rolling will often be employed to improve toughness, even tri-dimensional forging of blocks. The tool steel of the present invention can be obtained as a rod, wire or powder to be employed as welding alloy during welding. Even a die can be constructed by using a low cost casting alloy and supplying the steel of the present invention on the critical parts of the die by welding with a rod or wire made of a steel of the present invention or even laser, plasma or electron beam welded using powder made of the steel of the present invention. Also the tool steel of the present invention could be used with any thermal projection technique to supply it to parts of the surface of another material.
[0040] The tool steel of the present invention can also be used for the construction of parts suffering big thermomechanical loads, or basically any part prone to fail due to thermal fatigue, or with high toughness requirements and benefiting from a high thermal conductivity. The benefit coming from a faster heat transport or the lower working temperature. As examples: components for combustion engines (like motor block rings), reactors (also in the chemical industry), heat exchanging devices, generators or in general any machine for energy transformation. Dies for the forging (in open or closed die), extrusion, rolling, casting and tixo-forming of metals. Dies for the plastic forming in all its forms of both thermoplastic and thermosetting materials. In general any die, tool or piece that can benefit from an improved resistance to thermal fatigue. Also dies, tools or pieces benefiting from an improved thermal management, like is the case of dies for the forming or cutting of materials liberating great energy amounts (like stainless steel) or being at high temperature (hot cutting, press hardening).
EXAMPLES
[0041] Some examples are provided of how the steel composition of the invention can be more precisely specified for different typical hot working applications:
Example 1
[0042] For aluminium die casting of heavy pieces with considerable wall thickness, in this case as high as possible thermal conductivity is desired but with very high trough hardenability for a purely martensitic microstructure and notch sensitivity should be as low as possible, and fracture toughness as high as possible. This solution maximizes thermal fatigue resistance with a very good trough hardenability since the dies or parts constructed with the hot work tool steel have often very heavy sections. In this case such compositional range could be employed:
[0000] C eq : 0.3-0.34 Cr<0.1 (preferably % Cr<0.05%) Ni: 3.0-3.6
Si: <0.15 (preferably % Si<0.1 but with acceptable level of oxides inclusions)
Mn: <0.2 Mo eq : 3.5-4.5
[0043] Where Mo eq =% Mo+½% W
All other elements should remain as low as possible and in any case under 0.1%.
All values are in weight percent.
The relevant properties attainable are shown with two examples:
[0000]
Thermal
diffusivity
CVN
mm 2 /s
% C
% Mo
% W
% Ni
% Cr
% Si
% Mn
J
Tamb
400° C.
0.31
3.2
1.9
3.2
0.05
0.12
0.19
39
13.2
8.7
0.32
3.3
1.9
3.4
0.07
0.15
0.23
50
12.3
8.3
Example 2
[0044] For closed die forging. In this case a simultaneous optimization of wear resistance and thermal fatigue resistance has to be attained, so maximum CVN, and thermal diffusivity are desirable with an increased wear resistance (presence of primary carbides). In this case, Powder metallurgical tool steels within the following compositional range could be employed:
[0000] C eq : 0.34-0.38 Cr <0.1 (preferably % Cr<0.05%) Ni: 3.0-3.6
Si: <0.15 (preferably % Si<0.1 but with acceptable level of oxides inclusions)
Mn: <0.2 Mo eq : 5.0-7.0
[0045] Where Mo eq =% Mo+½% W
All other elements should remain as low as possible and in any case under 0.1%.
All values are in weight percent.
[0046] The relevant properties attainable are shown with two examples:
[0000]
Thermal
diffusivity
%
%
%
%
%
CVN
mm 2 /s
% C
Mo
W
Ni
Cr
% Si
Mn
J
Tamb
400° C.
0.345
4.4
3.4
3.1
0.05
0.05
0.20
36
12.4
8.5
0.357
4.6
3.5
3.4
0.07
0.11
0.21
32
12.2
8.4
Example 3
[0047] For hot cutting of sheets. In this case wear resistance has to be maximized, with a good trough hardenability and toughness. Thermal conductivity is very important to keep the temperature at the cutting edge as low as possible. In this case such compositional range could be employed:
[0000] C eq : 0.72-0.76 Cr <0.1 (preferably % Cr<0.05%) Ni: 3.4-4.0
Si: <0.15 (preferably % Si<0.1)
Mn: <0.4 Mo eq : 12-16
[0048] Where Mo eq =% Mo+½% W
All other elements should remain as low as possible and in any case under 0.1%.
All values are in weight percent.
[0049] The relevant properties attainable are shown with two examples:
[0000]
Thermal
diffusivity
Resil
mm 2 /s
% C
% Mo
% W
% Ni
% Cr
% Si
%Mn
J
Tamb
400° C.
0.74
10
8
3.5
0.04
0.045
0.21
200
11.0
7.7 | A hot work tool steel family with exceptional thermal diffusivity, toughness (both fracture toughness and notch sensitivity resilience CVN—charpy V-notch) and trough hardenability has been developed. Mechanical resistance and yield strength at room and high temperatures (above 600° C.) are also high, because the tool steels of the present invention present a high alloying level despite the high thermal conductivity. Given the exceptional resistance to thermal fatigue and thermal shock, wear resistance can be severely increased for many applications requiring simultaneously resistance to thermal cracking and wear like is the case for some forging and some parts of die casting dies. | 2 |
CROSS REFERENCE TO RELATED APPLICATION
[0001] This application claims the benefit of U.S. Provisional Application No. 61/531,139 filed on Sep. 6, 2011, entitled “Disposable Poo Scoop.” The patent application identified above is incorporated here by reference in its entirety to provide continuity of disclosure.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The present invention relates to waste collection and disposal devices. More specifically, the present invention relates to an inexpensive containment system for capturing waste that includes two adjacent receptacles connected by a means to join them. While in the standing position, a user stabilizes the female receptacle while applying a tangential force along the joining means, thus forcing the male receptacle to move toward the female receptacle, enclosing the desired waste and thereby providing a sanitary means for collection and disposal thereof.
[0004] The collection and proper disposal of pet waste represents a prevalent concern in modern society. Due to a direct correlation between the severity of this issue and the overpopulation of a specific area, major metropolitan cities were the first to realize the potential hazards of this growing problem. However, in recent years a steadily increasing population has shifted focus to newly affected rural areas that are beginning to face the consequences of not addressing this issue. Some municipalities have gone as far as enacting ordinances to neutralize the pet waste epidemic by requiring owners to dispose of the waste or risk a large fine.
[0005] A significant motivation behind the proper collection and disposal of pet waste relates to serious health concerns that can arise from its improper handling. Pet waste carries bacteria, parasites and viruses that can support Zoonosis, which are diseases that cross between species. These diseases can have a dramatic affect on humans, especially children, who have weaker immune systems and are more willing to play with foreign objects found in nature due to their curious temperament. According to the U.S. Center of Disease Control and Prevention (CDC) pet waste left unattended runs the risk of attracting the eggs of certain roundworms and parasites that lay dormant in the soil for years looking for a suitable host. These issues create a demand for a device that provides a sanitary and comfortable means to collect and dispose of pet waste.
[0006] Another important aspect of the pet waste epidemic is the corresponding environmental impact that is associated with improper disposal. Pet waste that is not sanitarily collected has a high probability of ending up in storm drains that run through our cities, some of which circumvent the local treatment facility opting to feed into local bodies of water. As time passes, the waste reduces oxygen levels within the water supply, emits ammonia and introduces bacteria, viruses and parasites to the ecosystem, all of which have a drastic impact on wildlife. The waste also contains nutrients that promote the formation of algae and weeds, which can detract from the natural beauty of the landscape thereby providing an unattractive, as well as unsafe, atmosphere. By these reasons a comfortable and efficient means for disposing pet waste is a necessity.
[0007] 2. Description of the Prior Art
[0008] The present invention addresses the prominent shortcomings relating to pet waste collection and disposal devices that commonly reside in the art. The majority of devices in the art contain similar methods for collecting the waste, which commonly requires a user to bend down below the waist, physically scoop up the waste in some form of a receptacle and then seal the receptacle thereby containing the waste. This action promotes possible skin contact with fecal matter which is a serious health concern, as well as limits the usability of the device relating to users who possess medical impairments, are unable to bend below the waste or would rather deploy the device with only one hand. The present invention addresses these issues with a solution that is deployed while remaining in the standing position and requires the use of only one hand. Therefore, the present invention differs dramatically in both structure and spirit from devices currently found in the art and is ideally suited for personal use when a user has a need for sanitarily removing pet waste from a given surface for future disposal. The following devices are the most prevalent in the prior art relating to waste collection and disposal devices.
[0009] U.S. Pat. No. 5,829,671 to Hawk is one such device in the art that describes a means for the collection and disposal of waste comprising a rectangular carton for holding waste and a handle for transportation. The carton itself comprises a front wall, a back wall, a pair of side walls, a bottom wall and a top wall that contains lateral gussets, which fold into a scoop configuration. Once the waste is deposited into the carton an integrated folding lid is deployed to fully enclose the waste to prevent any emanating odor from reaching a user. The Hawk device supplies a simple and inexpensive means to collect and dispose of waste yet fails to meet the level of ergonomics set forth by the present invention. In order to deploy the Hawk device a user must bend over to physically collect the waste, which can lead to contact with fecal matter thereby providing an opportunity to pass along various diseases to a user. The requirement to bend below the waste may also represent a physical impossibility relating to people with disabilities, causing undue frustration and hardship.
[0010] U.S. Pat. No. 3,885,266 to Nafziger is another device that describes a means for the collection and disposal of pet waste comprising a paperboard blank. In order to construct the intended device from the paperboard blank, a first fold is made and glue is applied to form a collapsed scoop with a detachable pusher. Once constructed, the final shape resembles a pyramid with one side open for the insertion of the pet waste. The overall effectiveness and ease of use relating to this device is subpar when compared to the present invention due to the complexity of assembly, additional time required to form the waste disposal receptacle and amount of space allotted for waste insertion. The paperboard structure leaves little room for error when navigating the device in the waste collection process, which can lead to contact with the waste, and therefore health problems for a user.
[0011] U.S. Pat. No. 4,974,893 to Grahn and U.S. Pat. No. 5,186,384 to Nelson are additional devices that describe a means for the collection and disposal of pet waste comprising a receptacle for the waste, an integrated handle for carrying the device and a tool meant to facilitate the transition of the waste into the receptacle. Once the waste is collected, a flap with a means to secure itself to the receptacle is folded over the open area providing a complete seal and therefore containment of the waste and odor. These devices propose an immediate problem to users with pet animals by requiring the use of both arms for the collection of waste. This discomfort may be more prominent for users with disabilities or users with larger pets who after defecating will continue to pull on their means for retention, which will cause frustration and undue stress. The requirement to use both hands in order to capture the waste also doubles the amount of a user's skin involved with the collection process thereby doubling the risk of contact between a user and the waste, raising immediate medical concerns. The present device negates these issues by providing a collection means requiring the use of only one hand that can be accomplished in the standing position.
[0012] U.S. Pat. No. 4,017,015 to Jefferson is another device that describes a collapsible kit for the collection and disposal of pet waste comprising a pair of receptacles that each contain a mirrored contour shape on their opened front surface for the purpose of forming a scoop like mechanism. When the desired waste to be collected is identified both of the receptacles approach the waste from either side, ultimately joining while containing the waste therein. Once the waste is collected a tab is revealed on the top surface of the combined receptacle to provide a comfortable means of transportation. This device provides a tightly sealed receptacle for containing the waste as well as an efficient means for transporting the waste yet does not address other prominent issues relating to these devices. By using both hands to collect the waste a user may be pulled by the retention device connected to their pet causing undo frustration and hardship. Also, the use of both hands doubles the risk of contact between a user's skin and the waste raising serious medical concerns.
[0013] Finally, U.S. Pat. No. 4,017,015 to Jefferson is a device that describes a collapsible kit for the collection, transport and disposal of pet waste comprising a plurality of flattened boxes, storage space for the contained waste and a means to transport the kit. Contained within the kit are two different types of boxes which originally are flattened to save space but when are unfolded provide a means to collect and seal the waste before being stored in the allotted storage space. Although this device provides a means to collect and store waste it also offers numerous problems that are common relating to similar devices in the art. Carrying multiple boxes to collect waste provides unnecessary discomfort to users who will most likely be collecting one or two deposits per trip. Also, when utilizing this device a user must bend down and use both hands to physically collect the waste. This action exposes the user to serious health issues if coming into contact with the waste as well as provides an opportunity for the animal to pull on its means for retention which will further increase the risk of fecal contact. The present invention negates these issues by deploying in the standing position and not requiring the use of both hands in order to collect the waste.
[0014] From the brief description of prominent devices in the art it is plainly gathered that the present invention provides a novel means to collect and dispose of waste and therefore substantially diverges in design elements from the prior art. Consequently it is clear that there is a need in the art for an improvement to existing waste collection and disposal devices. In this regard the instant invention substantially fulfills these needs.
SUMMARY OF THE INVENTION
[0015] In view of the foregoing disadvantages inherent in the known types of waste collection and disposal devices now present in the prior art, the present invention provides a new waste collection and disposal device wherein the same can be utilized for providing convenience for the user when collecting, transporting and ultimately disposing of waste.
[0016] It is therefore an object of the present invention to provide a new and improved waste collection and disposal device that has all of the advantages of the prior art and none of the disadvantages.
[0017] It is another object of the present invention to provide a waste collection and disposal device that can deploy while in the standing position, stabilizing the assembly with one foot and securing the waste with a free hand.
[0018] Another object of the present invention is to provide a waste collection and disposal device that is inexpensive and lightweight.
[0019] Another object of the present invention is to provide a waste collection and disposal device that does not require additional assembly or prep time prior to deployment.
[0020] Another object of the present invention is to provide a waste collection and disposal device that supplies a tight seal around any captured waste, containing any odors therein.
[0021] Another object of the present invention is to provide a waste collection and disposal device with a comfortable user interface for opening the receptacles, allowing for multiple deposits on a single excursion.
[0022] Another object of the present invention is to provide a waste collection and disposal device comprising a female receptacle with a tapered bottom edge to facilitate an efficient means to collect waste.
[0023] Another object of the present invention is to provide a waste collection and disposal device comprising a male and female receptacle in which the smaller dimensioned male receptacle contains the ability to slide into a female receptacle without any interference.
[0024] Another object of the present invention is to provide a secure attachment point for the means to join the male and female receptacles.
[0025] Yet another object of the present invention is to provide a comfortable means to pull the two adjacent boxes together when tension is applied by means of a soft, hypoallergenic and elastic material that acts as a handle.
[0026] Other objects, features and advantages of the present invention will become apparent from the following detailed description taken in conjunction with the accompanying drawings.
BRIEF DESCRIPTIONS OF THE DRAWINGS
[0027] Although the characteristic features of this invention will be particularly pointed out in the claims, the invention itself and manner in which it may be made and used may be better understood after a review of the following description, taken in connection with the accompanying drawings wherein like numeral annotations are provided throughout.
[0028] FIG. 1 shows a perspective view of the present invention while in an open configuration.
[0029] FIG. 2 shows a top view of the present invention in an open configuration prior to deployment.
[0030] FIG. 3 shows a cross section view of the present invention from a side perspective wherein the contoured bottom edge of the female receptacle and pull string attachment point are visualized.
[0031] FIG. 4 shows an isometric view of the present invention with an additional embodiment relating to another attachment point for the pull string.
DETAILED DESCRIPTION OF THE INVENTION
[0032] Reference is made herein to the attached drawings. Like reference numerals are used throughout the drawings to depict like or similar elements of the waste collection and disposal device. For the purposes of presenting a brief and clear description of the present invention, the preferred embodiment will be discussed as used for waste collection and disposal. The figures are intended for representative purposes only and should not be considered to be limiting in any respect.
[0033] Referring now to FIG. 1 , there is shown a perspective view of the waste collection and disposal device 11 as described in the present invention. The device comprises two adjacent receptacles connected by a means to join them, wherein the two receptacles differ in both size and function. The smaller receptacle, referred to as the male receptacle 13 , is initially deployed over the desired waste to be collected. Once the waste is fully enclosed, tension is applied to the means for joining the receptacles 14 , forcing movement of the male receptacle 13 toward the other, larger receptacle, aptly named the female receptacle 12 . During the joining process, the user may stabilize the female receptacle 12 by placing his or her foot thereon, allowing the male receptacle 13 to be drawn thereinto and the draw string joining means to overcome the friction therebetween. In order to facilitate a more stable union between the two receptacles a small rail may be attached on the interior surfaces of both female side walls with a corresponding and interlocking rail on the external surfaces of both male side walls. The rails will act as alignment points, positioning the incoming male receptacle in such a manner to reduce friction in the system, thereby reducing the required tension that is needed to join the receptacles. As the two receptacles join, the interior surface of the male receptacle's front wall pushes the waste toward the female receptacle until the chamfered bottom edge of the female receptacle acts as a scooping mechanism and captures the waste, thereby providing a means for sanitary containment.
[0034] The male and female receptacles are initially deployed with their respective center planes aligned in order to allocate the maximum and also equal tolerance relating to the distance between the male receptacle's outermost side wall surfaces and corresponding female receptacle's inner side wall surfaces. The means to join the male and female receptacles 14 , such as a pull string, is routed through the center of the most rear-facing wall of the female receptacle, passing through a clearance hole 15 and entering the open volume therein, until it is securely attached 16 to the center of the most rear-facing wall of the male receptacle. The other end of the pull sting is looped back onto itself and secured 17 using any one of an assortment of methods including glue, tape, a knot or a sewing stitch, thereby forming a handle 18 and providing convenience to a user while applying tension to the system. In order to provide a comfortable interface between the present device and a user, an elastic, non-allergenic and soft material is wrapped around the formed handle increasing ergonomics while joining the male and female receptacles. With the handle a user can sanitarily collect and dispose of the waste while in the standing position which negates medical concerns stemming from contact with animal waste.
[0035] Referring now to FIG. 2 , there is shown a top view of the present invention 11 in a working manner. The female receptacle 12 is shown to be larger than the male receptacle 13 , in order to facilitate the joining process without creating any interference. The pull string 14 is visualized entering the center of the female receptacle's rear wall 15 , traveling through the inner volume until being secured 16 to the center of the male receptacle's rear wall. At this point, the pull string mechanism is securely attached with an adhesive solution such as glue or tape, or a knotted solution involving the formation of a knot on the inner plane of the male receptacle's rear wall having a circumference that exceeds the corresponding pass through hole. With a secure attachment, a user can apply tension to the pull string at the handle, forcing the male receptacle to move toward the female receptacle thereby enclosing the waste for future disposal.
[0036] The present invention offers several important improvements relating to devices currently found in the art, such as one-handed use and the collection of waste while in the standing position. By circumventing any possible physical contact with the animal waste while remaining in the standing position, a user can negate various medical concerns such as the transference of bacteria, parasites and viruses. Users who have physical disabilities or are unable to bend below the waste also benefit from this important attribute due to their lack of flexibility or risk of serious physical harm that can occur from attempting to collect the waste. The one-hand collection aspect of the current invention provides users with a free hand to perform arbitrary but necessary tasks related to the waste collection process such as wielding a flashlight to better spot the target area or rein in an overactive pet.
[0037] Referring now to FIG. 3 , there is shown a cross section view of the present invention 11 while in a working manner. The male receptacle 13 is shown deployed over the waste to be collected 19 while the female receptacle 12 is beginning to encompass the male receptacle due to tension being applied to the pull string 14 . The pull string, fabricated from a durable and inexpensive material such as twine, rope, fishing line or string, is shown passing through a clearance hole on the female receptacle's rear wall 15 before traveling through the inner volume and being secured to the center of the male receptacle's front wall 16 . Once a secure attachment is established and tension applied to the system, the male receptacle 13 translates toward the female receptacle 12 with minimal distance existing between the exterior walls of the male receptacle and corresponding interior walls of the female receptacle 12 thereby negating any interference that can occur. A tapered or chamfered bottom edge 20 of the female receptacle is shown facilitating waste collection by providing a scooping mechanism to assist in propping up the waste. Once the waste is collected the device can be discarded in a sanitary fashion.
[0038] The present invention can be fabricated in numerous sizes in order to better serve the demand of users. Larger dimensioned male and female receptacles are an ideal solution for waste collection when dealing with larger breeds of dogs or other domesticated animals. Smaller versions can be made in order to provide a compact and easy to store device for smaller sized animals. The use of disposable, inexpensive and durable materials such as plastic, cardboard and composites can be used to fabricate the male and female receptacles in order to provide a low cost solution to users who have a need for waste collection and disposal devices.
[0039] Referring now to FIG. 4 , there is shown an isometric view of the present invention with an additional embodiment. The male 13 and female 12 receptacles are initially deployed with their respective center planes aligned in order to allocate the maximum and also equal tolerance relating to the distance between the male receptacle's outermost side wall surfaces and corresponding female receptacle's inner side wall surfaces. The means to join the male and female receptacles 14 , such as a pull string, is routed through the center of the most rear-facing wall of the female receptacle, passing through a clearance hole 15 and entering the open volume therein, until it is securely attached 16 to the center of the most rear-facing wall of the male receptacle. The other end of the pull sting is routed through the center of the male receptacle's front wall and attached, in close proximity to the pass through hole, on the front wall's interior surface 23 .
[0040] On occasion there exists a need to capture multiple deposits of waste on a single excursion. This need will require a user to open the disclosed invention by means of separating the male and female receptacles while contained waste exists therein. This can be safely accomplished by either manually pushing the male receptacle's rear wall facilitating it's separation, adding a small tab or handle like device to the center of the male receptacle's front wall which provides a convenient user interface or, as in FIG. 4 , fabricating a pull sting that is attached on both ends thereby providing a user with enough slack to create an interface sufficient to pull the receptacles apart. Once the receptacles are separated a user can re-deploy the device and capture both waste deposits for future sanitary disposal
[0041] It is therefore submitted that the instant invention has been shown and described in what is considered to be the most practical and preferred embodiments. It is recognized, however, that departures may be made within the scope of the invention and that obvious modifications will occur to a person skilled in the art. With respect to the above description then, it is to be realized that the optimum dimensional relationships for the parts of the invention, to include variations in size, materials, shape, form, function and manner of operation, assembly and use, are deemed readily apparent and obvious to one skilled in the art, and all equivalent relationships to those illustrated in the drawings and described in the specification are intended to be encompassed by the present invention.
[0042] Therefore, the foregoing is considered as illustrative only of the principles of the invention. Further, since numerous modifications and changes will readily occur to those skilled in the art, it is not desired to limit the invention to the exact construction and operation shown and described, and accordingly, all suitable modifications and equivalents may be resorted to, falling within the scope of the invention. | A system for the sanitary collection and disposal of pet waste is disclosed. The system comprises adjacent male and female receptacles connected by a pull string. The male receptacle contains an open bottom for the purpose of being deployed over targeted waste, while the female receptacle contains an opening most adjacent to the male receptacle in order to allow for their joining. The user secures the female receptacle and applies a tension to the pull string, allowing the smaller dimensioned male envelope to be pulled into the female receptacle interior, thereby capturing the waste within the assembly utilizing the tapered bottom edge of the female receptacle as a scooping mechanism. This process can be accomplished from the standing position while supporting the female receptacle with one foot and utilizing one arm to drawn in the male receptacle, providing flexibility for users and eliminates contact concerns with the waste product. | 4 |
[0001] This application claims the benefit of U.S. Provisional Patent Application Ser. No. 60/541,189 filed Feb. 2, 2004 which is hereby incorporated by reference in its entirety.
[0002] This invention was developed with government funding from NASA under grant no. 30324 awarded on Sep. 10, 2002. The U.S. Government may have certain rights.
FIELD OF THE INVENTION
[0003] The present invention relates generally to image monitoring systems and, more particularly, to a target identification and location system for identifying and precisely locating one or more targets, such as a wildfire, and a method thereof.
BACKGROUND
[0004] Current wildfire detection and monitoring systems utilize multispectral line scanning sensors on aerial platforms. Examples of these types of systems include the MODIS Airborne Simulator (MAS) sensor demonstrated by NASA Ames on the ER-2 and the US Forest Service PHOENIX System flown on a Cessna Citation Bravo. These systems have demonstrated substantial utility in detecting and monitoring wildfires from airborne platforms. However, these systems are custom engineered from the “ground up” relying on custom design and fabrication of complex opto-mechanical servos, sensors, readout electronics and packaging. As a result, these systems are subject to malfunction and are difficult to service.
[0005] A typical fire detection mission scenario involves imaging a 10 km swath from an aircraft at 3 km altitude over an area of fire danger. Missions are usually conducted at night to reduce false alarms due to solar heating. Existing systems employ a line scanning, mid-wave infrared (MWIR) band as the primary fire detection band along with a long wave infrared (LWIR) band which provides scene context. By combining the MWIR and LWIR data, a hot spot detected by the MWIR band can be located with respect to ground features imaged in the LWIR band. The line scanner provides excellent band to band registration, but requires a complex rate controlled scanning mirror and significant post processing to correct for scan line to scan line variations in aircraft attitude and ground speed. These sensitive scanning mechanisms are also prone to failure and are difficult to service. While the location of the detected fires is shown in the image, there is no actual computation of a specific ground coordinate for each fire pixel. This requires a specially trained image interpreter to analyze each image and manually measure the latitude and longitude of each fire pixel.
SUMMARY OF THE INVENTION
[0006] A target identification and location system in accordance with embodiments of the present invention includes at least three different infrared imaging sensors, a positioning system, and an image data processing system. The image data processing system identifies and provides a location of one or more targets based on image data from the at least three different infrared cameras and positioning data from the positioning system.
[0007] A method of identifying and locating one or more targets in accordance with embodiments of the present invention includes capturing one or more frames and recording position data for each of the frames. Each of the frames comprises a plurality of at least three different types of infrared image data. Each of the targets is identified and a location is provided based on the three different types of captured infrared image data in each of the frames and the recorded position data.
[0008] The present invention provides a system and method for identifying and providing a precise location of one or more targets, such as a wildfire. More specifically, the present invention provides a significant increase in wildfire detection and monitoring capability, real time automated geo-location of a target, a significantly improved operational reliability and ease of use, and lower operating costs than with prior sensing systems. The present invention also has a lower false alarm rate than with prior fire sensing systems allowing reliable day and night operations
BRIEF DESCRIPTION OF THE DRAWINGS
[0009] FIG. 1 is a perspective view of a plane with a target identification and location system in accordance with embodiments of the present invention;
[0010] FIG. 2 is a block diagram of the target identification and location system shown in FIG. 1 ;
[0011] FIG. 3 is a section of the plane shown in FIG. 1 with a partial, perspective view of the supporting assemblies for the target identification and location system;
[0012] FIG. 4 is a perspective view of the gimbal assembly;
[0013] FIG. 5 is a side, partial cross-sectional view of the gimbal assembly shown in FIG. 4 ;
[0014] FIG. 6 is a perspective view of an imaging system in the target identification and location system;
[0015] FIG. 7 is a table of specifications for one example of the target identification and location system;
[0016] FIG. 8 is a functional block diagram of a method for identifying a target in accordance with embodiments of the present invention;
[0017] FIG. 9 is a functional block diagram of a method for detecting a target in accordance with embodiments of the present invention; and
[0018] FIG. 10 is a graph of multi-spectral images to discriminate a fire from a solar reflection.
DETAILED DESCRIPTION
[0019] A target identification and location system 10 in accordance with embodiments of the present invention in an aircraft 15 is illustrated in FIGS. 1-6 and 8 . The target identification and location system 10 includes an imaging system 11 with a LWIR imaging sensor 12 , a MWIR imaging sensor 14 , a short wave infrared (SWIR) imaging sensor 16 , a very near infrared (VNIR) imaging sensor 18 , a global positioning system 20 , an inertial measurement system 22 , and an image data processing system 24 , although the target identification and location system 10 can include other types and numbers of components connected in other manners. The present invention provides a system 10 and method for identifying and providing a precise location of one or more targets, such as a wildfire. More specifically, the present invention provides a significant increase in wildfire detection and monitoring capability, real time automated geo-location of a target, a significantly improved operational reliability and ease of use, and lower operating costs than with prior sensing systems.
[0020] Referring to FIGS. 1 and 3 - 5 , the target identification and location system 10 is mounted in an electronics rack assembly 26 and a sensor mounting system 28 in an aircraft 15 , although the target identification and location system 10 can be mounted with other types of mounting systems and in other types of vehicles. The electronics rack assembly 26 is used to secure the image data processing system 10 in the aircraft, although the image data processing systems could be secured in other manners in other locations. The sensor mounting system 28 is mounted to a floor 30 of the aircraft 15 above an opening or window, although the sensor mounting system 28 could be mounted on other surfaces in other locations, such as on the outside of the aircraft 15 .
[0021] The sensor mounting assembly 28 includes a single axis positioning assembly 32 , such as a gimbal assembly, that supports and allows for pivotal motion of the imaging system 11 about a first axis A-A, although other types of mounting systems for the single axis positioning assembly could be used. The single axis positioning system 32 allows the line of sight of the LWIR imaging sensor 12 , the MWIR imaging sensor 14 , the SWIR imaging sensor 16 , the VNIR imaging sensor 18 in the imaging system 11 to pivot to provide a wide field of view for imaging the ground. In this particular embodiment, the lines of sight of the LWIR imaging sensor 12 , the MWIR imaging sensor 14 , the SWIR imaging sensor 16 , the VNIR imaging sensor 18 can be pivoted across a swath +/−40 degrees for a total imaging swath of +/−60 degrees (taking into account the 40 degree field of view for each imaging sensor 12 , 14 , 16 , and 18 ), although the lines of sight can be pivoted other amounts and the imaging sensors could have other ranges for the field of view.
[0022] Referring to FIGS. 1-3 , 5 , 6 , and 8 , the imaging system 11 includes LWIR imaging sensor 12 , the MWIR imaging sensor 14 , the SWIR imaging sensor 16 , the VNIR imaging sensor 18 which are each used to capture infrared images or infrared image data for target identification and location to provide a location of the one or more targets, although the imaging system 11 can include other types and numbers of imaging sensors, such as a visible imaging sensor 19 for capturing one or more visible images in each of the frames. In this particular embodiment, the spectral ranges for the LWIR imaging sensor 12 is about 8.0-9.2 microns, the spectral range for the MWIR imaging sensor 14 is about 3.0-5.0 microns, the spectral range for the SWIR imaging sensor 16 is about 0.9-1.7 microns, and the spectral range for the VNIR imaging sensor 18 is about 0.4-0.9 microns, although the imaging sensors could have other spectral ranges which are either spaced apart or partially overlap and other types of imaging sensors can be used. The LWIR imaging sensor 12 , the MWIR imaging sensor 14 , the SWIR imaging sensor 16 , the VNIR imaging sensor 18 are large area format camera systems, instead of line scanning imaging systems, although systems with other types of formats can be used. The imaging system 11 transmits data about the captured image data to the image data processing system 24 via an image interface system 34 .
[0023] Referring to FIGS. 2, 3 , and 8 , the global positioning system 20 and the inertial measurement system 22 are mounted to the sensor mounting assembly, although other types and numbers of positioning systems can be used. The global positioning system 20 includes provides precise positioning data and the inertial measurement system provides inertial measurement data about each of the frames of captured image data by the imaging system 11 to a position processor 36 . The global positioning system 20 also provides precise data about the line of sight of the cameras. Additionally, a precision encoder and drive motor system 38 is mounted to a drive axis A-A for the single axis positioning system 32 and provides position data about the imaging system 11 to the position processor 36 . The position processor 36 determines the precise location of each of the frames of image data based on position data from the global positioning system 20 , the inertial measurement system 22 , and the precision encoder and drive motor system 38 and transmits the locations to the image data processing system 24 , although the location can be determined by other systems, such as the image data processing system 24 .
[0024] The data image processing system 24 includes a central processing unit (CPU) or processor 40 , a memory 42 , an input device 44 , a display 46 , and an input/output interface system 48 which are coupled together by a bus or other communication link 50 , although other types of processing systems comprising other numbers and types of components in other configurations can be used. The processor 40 executes a program of stored instructions for one or more aspects of the present invention as described herein, including a method for identifying and providing a precise location for the one or more targets as described and illustrated herein.
[0025] The memory 42 stores the programmed instructions for one or more aspects of the present invention as described herein including the method identifying and providing a precise location for the one or more targets as described herein, although some or all of the programmed instructions could be stored and/or executed elsewhere. The memory 42 also stores calibration and correction tables for each of the imaging sensors 12 , 14 , 16 , 18 , and 19 in the imaging system 11 in tables. A Digital Elevation Model (DEM) is also stored in memory 42 and is used to provide terrain elevation information which will be used by the processor 40 for precise geo-location of the imagery. Additionally, vector data from a geospatial information system (GIS), such as roads, water bodies and drainage, and other manmade and natural landscape features I stored in memory 42 and will be used in the processor 40 to combine with or annotate the imagery. Other data sets stored in memory 42 may include relatively low resolution imagery from sources such as LANDSAT that would be used by the processor 40 to provide overall scene context. A variety of different types of memory storage devices, such as a random access memory (RAM) or a read only memory (ROM) in the system or a floppy disk, hard disk, CD ROM, or other computer readable medium which is read from and/or written to by a magnetic, optical, or other reading and/or writing system that is coupled to the processor, can be used for memory 42 to store the programmed instructions described herein, as well as other information.
[0026] The input device 44 enables an operator to generate and transmit signals or commands to the processor 40 . A variety of different types of input devices can be used for input device 44 , such as a keyboard or computer mouse. The display 44 displays information for the operator. A variety of different types of displays can be used for display 44 , such as a CRT display. The input/output interface system 48 is used to operatively couple and communicate between the image data processing system 24 and other devices and systems, such as the LWIR imaging sensor 12 , MWIR imaging sensor 14 , SWIR imaging sensor 16 , VNIR imaging sensor 18 , global positioning system 20 , inertial measurement system 22 , and precision encoder and drive motor system 38 . A variety of communication systems and/or methods can be used, such as a direct connection, a local area network, a wide area network, the world wide web, modems and phone lines, and wireless communication technology each having their own communications protocols.
[0027] By way of example only, a table of specifications for one example of the target identification and location system 10 is shown in FIG. 7 , although the target identification and location system 10 can be configured to have other specifications. Also, by way of example only, the weight of the target identification and location system 10 is estimated to be less than 220 lb and maximum operating power less than 550 W. As a result, the present invention weighs less and uses less power than prior systems.
[0028] The operation of the target identification and location system 10 in accordance with embodiments of the present invention will now be described with reference to FIGS. 1-6 and 8 - 10 . The target identification and location system 10 in the aircraft 15 collects a mosaic of frames across a full swath by “stepping” the line of sight of the imaging system 11 across the swath using the single-axis positioning system 32 with the drive motor and position encoder system 38 . The drive motor and position encoder system 32 steps the imaging system 11 through different positions about the axis A-A and transmits the position data about the imaging system 11 for each positions of each frame of the captured image data to the image data processing system 24 . After a full swath of image data is acquired, the single-axis positioning system 32 resets the line of sight of the imaging system 11 to complete the cycle. By way of example only, a full swath is acquired in about eight seconds and typically no more than seventeen seconds, although other amounts of time to collect a full swath can be used. As a result, the present invention does not need complex and expensive rate controlled servo mechanisms to capture frames, since each frame is captured from a static position.
[0029] In these embodiments, four frames are acquired by the imaging system 11 over the swath which covers an area of up to 10 km, although other numbers of frames can be acquired over other areas. The imaging system 11 captures each of the four frames across the swath using at least three of the LWIR imaging sensor 12 , MWIR imaging sensor 14 , SWIR imaging sensor 16 , and VNIR imaging sensor 18 to capture image data in three spectral bands, although other numbers and types of imaging sensors can be used and other spectral bands can be acquired. To accurately identify one or more targets, such as wildfires, the present invention acquires image data in LWIR, MWIR, and SWIR bands during nighttime hours and acquires image data in LWIR, MWIR, SWIR, and VNIR bands during daylight. With respect to the image data which is acquired, the image data processing system 24 retrieves calibration and correction data from tables stored in memory 42 for each of the imaging sensors 12 , 14 , 16 , and 18 in the imaging system 11 and makes adjustments to the captured image data based on the retrieved calibration and correction data.
[0030] Next, the image data processing system 24 with the position processor 36 performs geo-referencing and registration on the corrected and calibrated image data. The global positioning system 20 , the inertial measurement system 22 , and the drive motor and encoder system 38 provide the image data processing unit 24 and the position processor 36 with the global position data, inertial measurement data, and imaging system 11 positioning data, respectively, for each frame of the corrected and calibrated image data, although other positioning data could be provided. The image data processing system 24 with the position processor 36 also receive data about the operating parameters of the aircraft 15 at the time the frames of image data are captured. As the aircraft 15 moves while collecting the full swath, there is a slight in-track offset from frame to frame of about 61 pixels (12% of the image), although the offset can vary depending on the operating characteristics of the aircraft 15 , for example the speed of the aircraft 15 . The motion of the aircraft 15 will also produce less than 0.5 pixel of image motion smear during a nominal 15 ms integration time at a nominal ground speed of 180 knots, although the smear will also vary depending on the operating characteristics of the aircraft 15 . The image data processing system 24 with the position processor 36 use the obtained position data and the data related to the slight in-track offset and the image motion smear to adjust the image data in each of the frames. The image data processing system 24 with the position processor 36 obtains a precise measurement of the orientation and position of each imaging sensor 12 , 14 , 16 , and 18 for each frame of imagery. The position processor 36 utilizes data from a combination of a precision GPS 20 and an inertial measurement unit 22 . The image data processing system 24 combines the measured image sensor position and orientation data with known camera internal orientation geometry and the DEM using photogrammetric techniques to calculate a fully corrected image for each frame.
[0031] The image data processing system 24 performs a two step registration process on the image data from the imaging system 11 for each of the frames to create a substantially full swath mosaic. First, the image data processing system 24 performs a band to band registration which aligns the image data for the three different captured bands for each frame into one frame. Next, the image data processing system 24 performs a frame to frame registration which produces a full swath mosaic. By way of example, the image data processing system 24 may use a method for frame to frame registration, such as the method and apparatus for mapping and measuring land disclosed in U.S. Pat. No. 5,247,356, which is herein incorporated by reference in its entirety. The relative alignment of each of the image sensors 12 , 14 , 16 , and 18 is calculated through a pre-operation calibration process in which the image sensors 12 , 14 , 16 , and 18 simultaneously image a known set of ground or laboratory targets. The relative offsets and rotations are determined from this image set and programmed into the processor 40 .
[0032] Next, the image data processing system 24 processes the image data to identify and discriminate a target, such as a wildfire, from other items. Typical processing by processor 40 may include the calculation of a ratio of apparent brightness for each pixel and comparing that to a pre-determined threshold. The inclusion of a third spectral band allows the application of more sophisticated algorithms than would be possible using only two bands. One example of this processing is illustrated in FIG. 10 where image data from LWIR imaging sensor 12 , the MWIR imaging sensor 14 , the SWIR imaging sensor 16 , and the visible imaging sensor 19 to identify and discriminate a wildfire from a solar reflection.
[0033] Next, the image data processing system 24 generates an output, such as an annotated map, on the display 46 to identify the type and location of the target(s), although other types of displays could be generated or stored for later use. To add information value to the displayed imagery, relevant GIS vector data may be inserted as an overlay. Low resolution data, for example RGB LANDSAT data, may be displayed alongside LWIR data to provide a visible context to the imagery.
[0034] The present invention provides a system and method for identifying and providing a precise location of one or more targets, such as a wildfire. In particular, the present invention provides the wildfire management community with the capability to detect and monitor wildfires from either manned or UAV aerial platforms. The present invention extends the operational envelope into the daytime and also improves operability. The extension of mission capability into the daylight hours is enabled by the use of a SWIR imaging sensor 16 in addition to the bands provided by the MWIR imaging sensor 14 and the LWIR imaging sensor 12 . The SWIR imaging sensor 16 helps to discriminate fire targets in daylight and also for detecting hot fires at night.
[0035] A very high resolution visible imaging sensor 19 can be used with the imaging system 11 to provide detailed scene context during daylight operations for each of the captured frames. The visible imaging sensor 19 would capture image data with the three or more of the LWIR imaging sensor 12 , MWIR imaging sensor 14 , SWIR imaging sensor 16 , and VNIR imaging sensor 18 which are capturing image data. As a result, the present invention can not only identify and provide the location of one or more targets, but also can also provide a visible image of each of the targets. Use of a high resolution visible imaging sensor 19 also provides excellent spatial context and improves the frame registration process.
[0036] Having thus described the basic concept of the invention, it will be rather apparent to those skilled in the art that the foregoing detailed disclosure is intended to be presented by way of example only, and is not limiting. Various alterations, improvements, and modifications will occur and are intended to those skilled in the art, though not expressly stated herein. These alterations, improvements, and modifications are intended to be suggested hereby, and are within the spirit and scope of the invention. Additionally, the recited order of processing elements or sequences, or the use of numbers, letters, or other designations therefor, is not intended to limit the claimed processes to any order except as may be specified in the claims. Accordingly, the invention is limited only by the following claims and equivalents thereto. | A system and method of identifying and locating one or more targets includes capturing one or more frames and recording position data for each of the frames. Each of the frames comprises a plurality of at least three different types of infrared image data. Each of the targets is identified and a location is provided based on the three different types of captured infrared image data in each of the frames and the recorded position data. | 6 |
STATEMENT OF GOVERNMENT INTEREST
This invention was made with United States Government Support under Cooperative Agreement 70NANB5H1047 awarded by the U.S. Department of Commerce, National Institute of Standards and Technology. The United States Government has certain rights in the invention.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The invention in general relates to composite structures and more particularly to tubular composites with an end connection.
2. Description of Related Art
The use of composite materials in place of metal for various structures is desirable for many reasons, including weight reduction, corrosion resistance, durability and increased strength.
One type of structure which finds use in a variety of applications is a tube, or cylinder, which must be joined to another similar or dissimilar structure, at either or both ends. Accordingly, an end piece, of a material such as metal, is provided as the cylinder termination for the joining process. The use of adhesives for bonding the metal end piece to the composite cylinder may be less than satisfactory under certain conditions, particularly in the presence of large bending moments or axial loads which leads to debonding. Extreme environmental conditions such as immersion in water can weaken the bond. Large temperature changes can cause joint failure due to coefficient of thermal expansion mismatch induced thermal stresses.
Mechanical fasteners have also been used for securing the composite cylinder to the metal end piece. However, this form of connection requires drilling holes which tends to weaken the composite. Their performance also degrades under extreme environmental conditions of high temperature and immersion in water.
In another arrangement, such as described in U.S. Pat. No. 4,701,231 a composite cylinder has an end which is wound over, and bonded to, a contoured end piece which is of such geometrical shape that it is locked in place. This geometrical lock type joint typically has a bonded interface between the composite and end piece, however under large load conditions the bond may fail, allowing undesired relative movement between the composite and the end piece. Or it may become highly loaded during fabrication or use due to temperature changes. As with a conventional bonded joint when the bond fails an undesirable gap may open up.
The present invention provides a solution to the end joint problem so as to allow for a structure which can accommodate relatively high axial loads and bending moments without failure of the joint or without excessive movement.
SUMMARY OF THE INVENTION
A composite-to-end connection arrangement in accordance with the present invention includes a hollow cylinder of composite material which extends along a central longitudinal axis. An end connection assembly includes first and second longitudinally arranged segments coaxial with the axis.
The end of the cylinder is formed about the segments so as to assume the contour thereof, the contour having a predetermined shape so as to prevent withdrawal of the segments from the cylinder.
A snap ring of rest diameter D and having first and second ends moveable relative to one another is compressed to a diameter smaller than D and is inserted into the end connection assembly. The first and second segments are separated and the snap ring assumes its larger diameter condition in a position between the segments, separating the segments and forcing them into intimate contact with the inner contoured surface of the cylinder to limit axial movement of the assembly due to a predetermined load condition.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 illustrates one of many applications for the present invention.
FIGS. 2A to 2C illustrate a geometric lock joint of the prior art.
FIGS. 3A to 3C illustrate the principle involved in the present invention.
FIG. 4 is an axial cross-sectional view of an embodiment of the invention.
FIG. 5 illustrates one type of snap ring which may be utilized in the present arrangement.
FIGS. 5A and 5B illustrate another type of snap ring which may be utilized in the present arrangement.
FIGS. 6 and 7 illustrate the placement of the snap ring of FIG. 5 into the structure of FIG. 4.
FIG. 8 illustrates a marine riser section made in accordance with the present invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Although the present invention finds use with a variety of structures including rocket motor cases, pressure vessels and missile launcher tubes, it will be described by way of example with respect to a marine riser such as the drilling riser illustrated in FIG. 1.
In FIG. 1 a riser arrangement 10 made up of a plurality of riser sections 12 extends from a floating platform 14 at the surface to drilling equipment 16, such as a blowout preventer, located on the bed 18 of a body of water. The primary function of the riser 10 is to guide drill pipe and tools to the well bore and to provide a return path for drilling mud which is pumped down the center of the drill pipe to cool and lubricate the drill bit, flush tailings out of the bore and balance the hydrostatic pressure of the formation being drilled through.
Drilling risers are generally of medium strength steel which create significant weight loads for the floating platform 14. Accordingly, advanced composite drilling risers are being considered as a replacement for steel thereby significantly reducing the deck weight of the riser system, and allowing a greater number of riser sections to be carried, to extend the drilling capabilities to greater depths.
One key to implementing composite technology in drilling risers is the development of composite-to-steel structural joints between the composite cylinder and a steel end connector. A similar need exists in the case of production marine risers, which are similar to drilling risers but are of lesser diameter and are used after a producing well is established.
FIG. 2A illustrates, in cross-sectional view, an end connection for a composite cylinder in an arrangement which prevents the connection from being withdrawn from the composite cylinder. The structural arrangement, more fully described in the aforementioned U.S. Pat. No. 4,701,231, includes a composite cylinder 20 which extends along a central longitudinal axis C. Cylinder 20 has an end portion 21 formed about an internal ring 22, such as by filament winding, to thereby conform to the contour of the ring 22. The contour of the ring 22 is defined by hyperboloidal surface portions 24 and 25 on either side of an isotensoidal, or circular arc surface portion 26, which defines the maximum diameter of the ring 22.
The arrangement typically incorporates an optional adhesive bond 28 between the ring 22 and the inner surface of the cylinder end 21. If an elevated temperature cure composite is used, its coefficient of thermal expansion needs to be tailored by varying the fiber type and orientation during winding so that it matches that of the material being wound over, typically steel, aluminum or titanium. A large coefficient of thermal expansion mismatch yields high residual thermal stresses in the bondline between the composite and metallic ring which may lead to debonding as the parts cool down from an elevated temperature. This is illustrated in FIG. 2B by debonded portions 30 and 31. A similar gap can occur if there is no adhesive at the interface with temperature environmental changes.
Stress concentrations and high residual thermal stresses can lead to premature bond failure as can poor bond quality, environmental effects and fatigue. Complete bond failure, as depicted by numeral 34 in FIG. 2C, results in a relatively large displacement, d, between the cylinder 20 and the initial position of ring 22, when subjected to an axial load represented by arrow 36. Although the ring 22 is not withdrawn from the cylinder 20 as a result of the axial load, large relative motions will cause damage to the composite cylinder 20 due to fretting and abrasion. The relative motion will also damage an inner liner, if used.
FIGS. 3A to 3C serve to illustrate the basic concept which the present invention utilizes. In FIG. 3A, a cylinder 40 of composite material extends along, and surrounds a central longitudinal axis C. An end 41 of the cylinder 40 is formed around an end connection assembly 42, having a contour which will prevent its withdrawal from the cylinder. The forming may be accomplished by a variety of composite fabrication processes such as filament winding, tape laying, roll wrapping or hand layup, to name a few. The end connection assembly may be of a metal such as steel and its contour may be as previously described in FIG. 2A with respect to ring 22.
The end connection assembly however in the present invention includes two longitudinally displaced segments, 42a and 42b which initially touch one another such as at the point of maximum outside diameter with one, or both, of the segments being free to move in an axial direction. That is, by use of a mold release agent covering their surface, they are not bonded to the inner surface of the cylinder.
The two segments 42a and 42b are relatively forced apart, as indicated by arrows 44 and 45 in FIG. 3B, leaving a gap g between them. The separation process may be accomplished by applying an external force to the outermost segment 42b, while holding segment 42a immobile or by tooling which contacts and separates both segments 42a and 42b to preload the composite-metal interface.
Once separated, and as indicated in FIG. 3C, a spacer 46 is inserted into the gap between the ends of segments 42a and 42b, the external separating force is removed, and the restoring force, as indicated by arrows 47 and 48, maintain the spacer 46 in position.
As shown in these Figs., as well as in the specific embodiment of the invention to be described, a portion, such as 49, of one of the segments extends past the end of the composite cylinder. An external connector may then be coupled to this extended portion for joining the cylinder to another structure.
In FIG. 4, illustrating one embodiment of the invention, a composite cylinder 60 extends along, and surrounds a central axis C. An end 62 of the cylinder 60 is formed around an end connection assembly 64, having a contour which will prevent its withdrawal from the cylinder, as previously described.
The end connection assembly includes first and second longitudinally displaced segments 64a and 64b coaxial with central axis C, with each having a respective end 66a and 66b in an overlapping relationship. In order to reduce the amount of displacement when a preloading is applied and to reduce stresses in the joint area, a circumferential overwrap 68 may be applied over the end of the cylinder 60. The cylinder 60 and overwrap 68, which may be formed by any number of manufacturing processes, as previously described, do not cover the extreme end of segment 64b thus allowing a portion 70 to be available for attachment to another structure.
In the present invention, the two segments 64a and 64b are relatively pulled apart and in so doing the overlapping ends 66a and 66b will form a gap or groove. A split, or snap ring is placed into the formed groove thus separating and maintaining the two segments 64a and 64b in a forced apart condition against the inner contoured surface of the cylinder 60 to thereby limit axial movement of the assembly 64 due to predetermined load conditions.
One type of snap ring which may be utilized is illustrated in FIG. 5. The snap ring 74, coaxial about an axis A, has ends 75 and 76 which, in the embodiment illustrated, are separated by a split or gap 77. The ring 74 has a rest diameter D, a radial thickness R and an axial thickness T. The ring 74 is of a material such as steel so as to allow it to be compressed in a manner so as to reduce its diameter. In the embodiment of FIG. 5, ends 75 and 76 may be brought together tending to close gap 77 and reduce diameter D to a point whereby the ring may be inserted into segment 64b of end connection assembly 64. To accomplish the gap and diameter reduction, the ends 75 and 76 may be provided with means such as a series of apertures 78 to allow for the insertion of a tool or other means for drawing the two ends together.
Other embodiments of the snap ring may include those designs wherein there is a minimal, diagonal or even no perceptible gap, and wherein the reduction in diameter is accomplished by sliding one end of the ring past the other end in an overlapping relationship. By way of example, FIG. 5A illustrates a snap ring 80 having ends 81 and 82 which are relatively close to one another and which define a narrow diagonal gap 63. The ends 81 and 82 are drawn together whereby the diagonal surfaces of the ends slide over each other such that, as illustrated in FIG. 5B, the ends are axially displaced and are in an overlapping relationship. Apertures 84 in ends 81 and 82 allow the ends to be secured to a mandrel, or the like, for insertion of the snap ring 80 into the end connection assembly.
With additional reference to FIG. 6, and with reference to the snap ring as illustrated in FIG. 5, after the ring diameter has been sufficiently reduced it is inserted into segment 64b and held in position by means of a series of brackets 86 temporarily secured to the inside surface of segment 64a by means of fasteners 88. Each bracket 86 includes a cut out 90 which is fit over the ring 74 to immobilize it while the segments 64a and 66b are drawn apart.
When groove 92, formed by the separating segments 64a and 64b, is of sufficient axial length T, the ring 74 will snap into position into groove 92, again assuming its rest diameter, and maintaining the two segments in a forced apart condition. At this time, and as indicated in FIG. 7, the brackets 86 may be removed and, if desired the cavity 94, formed at the same time as groove 92, may be filled with a resin material introduced via passageway 96, and to aid in the filling process an additional passageway 97 may be provided as an outlet for entrapped air or for a vacuum connection. In order to provide for a smooth interior it is preferable that the formed groove 92 have a depth equal to the radial thickness R of the ring 74. In this regard, the gap 80, in FIG. 7 may be filled in with a material to provide a gapless smooth interior.
As previously brought out, the embodiment of the invention includes a feature wherein a portion 70 of segment 64b extends past the end of the composite cylinder 60. An external connector such as a flange, threaded connector, grooved connector, or the like, may then be coupled to this extended portion for joining the cylinder to another structure.
By way of example, and with reference to FIG. 8, there is illustrated, partially in section, a typical marine riser 100 including end connection arrangements 102 at both ends and constructed in accordance with the teachings herein. With an end connection assembly 104 having segments made of a metal such as steel, an external connector such as steel flange 106 may be welded to the exposed ends of the segments at either end of the riser section 100. The flanges 106 may then be bolted to the flanges 106' of respective adjacent riser sections, with the process being repeated, thus resulting in a light weight marine riser system. | An end of a composite cylinder is formed about an end connection assembly having two longitudinally arranged pieces having a contour which prevents the withdrawal of the end connection assembly from the cylinder. The two pieces of the end connection assembly are relatively forced apart and a snap ring having a certain rest diameter is reduced in diameter and inserted into the end connection assembly to a position between the pieces. The snap ring then assumes its rest diameter positioned between the pieces, forcing them to maintain intimate contact with the inner surface of the cylinder, thus removing any residual gap from the assembly process and/or preloading the interface between the end of the composite cylinder and the end assembly prior to application of an axial load. | 8 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to an apparatus for rearranging information in a communication system comprising a plurality of loops for transmitting a plurality p of outgoing time-division multiplexed information signals containing information obtained from a plurality p of incoming asynchronous time-division multiplexed digital information signals, such signals being identical as regards their configuration and being included in fast and slow rate channels CI and CS respectively, the fast rate channels CI being formed by time slots arranged in a base frame, the slow rate channels CS being formed by time slots distributed in successive base frames and arranged in a multiframe comprising a plurality of base frames. The information rearranging apparatus has p respective data inputs E1, E2, . . . , Ep for the incoming multiplexed signals and p respective data outputs S1, S2, . . . , Sp for the outgoing multiplexed information signals.
The apparatus may be employed in a local area network, that is to say, a digital communications system including telephony, specifically telephone communication, and data transmission; it may be used in business undertakings such as offices, factories or the like or aboard vessels, and permits considerable reduction of the amount of necessary wiring while permitting simultaneous transmission of a large number of independent communications.
2. Description of the Related Art
French Patent Specification 2 526 614 in the name of the Applicants, which corresponds to U.S. Pat. No. 4,520,479, discloses a time division multiplexed communication system comprising a single closed loop. This system permits, with conventional technology and a moderate multiplex rate, to connect in series in the loop about a hundred connecting units, denoted as concentrators, each concentrator being connected to about fifteen subscribers, which is suitable for approximately 1500 to 2000 users connected to the system. If the number of users exceeds 2000, this will then pose the general technical problem of enhancing the capacity of the system. This problem may be solved, as one of the possible solutions, by modifying the system architecture.
SUMMARY OF THE INVENTION
The solution provided by the invention is to provide a TDNL system comprising a plurality of loops which all pass through a central unit called a superpilot.
This solution, for enhancing the capacity of the local network, provides the advantage of retaining the same characteristics for the time-division multiplexed signals in all the various loops as in single loop; the concentrators can also remain the same, which makes it possible to enhance the capacity of a single loop system in a very simple way, first by adding concentrators at an arbitrary place in such loop and then by introducing one or more additional loops and superpilot apparatus as described herein.
The aforementioned technical problem, in the case of such a multiloop system, is to permit any user of the system to communicate with any other user or be able to teleconference while augmenting to the least possible extent the transmit time of the information signals between users.
According to the invention the technical problems indicated hereinbefore are solved because the superpilot apparatus, which is apparatus for rearranging information as indicated in the first paragraph, is characterized in that the p data inputs thereof are connected to respective units SRI for synchronising the p incoming multiplexed signals and rearranging the information signals of the high rate channels CI, and in that the p outputs of the units SRI are connected in parallel to p inputs of an interloop switching unit CII for the channels CI, the unit CII comprising a first switching matrix, and to p inputs of a unit RCIS for rearranging and interloop switching of the low rate channels CS, this unit RCIS comprising delay units and a second switching matrix. The p information outputs of the unit CII are paired with the p information outputs of the unit RCIS, the respective pairs of outputs being connected to first and second input terminals of respective combination circuits. The p combination circuits produce at their respective outputs S1, S2, . . . , Sp, the said p outgoing synchronous multiplexed signals.
The basic idea of the invention consists of first synchronising the incoming multiplexed signals appearing at the inputs of the apparatus and which have different time shifts and, subsequently, transmitting to separate units according to the desired loop configuration(s) the information relating to the actual information channels (the CI channels) and also the information relating to the signalling channels (the CS channels) which are rearranged simultaneously.
It should be observed that rearrangement of the channels CI, which are the fast rate information channels, is effected at the input of the apparatus by the units SRI. When a switching configuration in the unit CII interconnects a number of loops, for example 3, which have time shifts for which the closing and opening of 3 switches is necessary, a long loop is thus created provisionally, constituted by these three elementary loops through which the rearrangement of the channels CI is effected three times in succession by 3 different SRI units, which trebles the information rearranging time compared to that of a single loop. For an elementary information rearranging time equal to a base frame, for example 250 μs, it is certainly tolerable if the number of elementary loops to be interconnected remains low, which is usually the case. Alternatively, the rearranging time of the signals in channel CS is long, preferably equal to the time of the multiframe and, for example, equal to 64 ms for a single-loop system. It is not advisable to augment this time, as a result of an interconnection of various elementary loops, so as to avoid the phenomenon of echoes occurring for the user stations incorporated in the long loop created by the aforesaid interconnection configuration.
In order to obviate the constraint mentioned in the preceding paragraph, an advantageous embodiment of the invention is characterized in that each of the p inputs of the said rearranging and interloop switching unit RCIS for the channels CS is connected to a line comprising p series-arranged delay units, and in that the output of each delay unit is connected to a column of the said second switch matrix of which each line is connected to one of the p outputs of the RCIS.
With this structure for the unit RCIS it is then possible for a system comprising 4 loops, for example, in steps of 0.25; 0.5; 0.75, to modulate the rearranging time of the channels CS by means of an elementary loop and to provide, for a multiloop configuration for a given multiloop signalling channel, this configuration being spread in time owing to the opening and closing of the associated switches of the matrix, that the accumulative delays introduced for the rearrangement of the channels CS of the elementary loops is equal to the delay for a single loop, that is, equal to the time of the multiframe. In this case the running numbers of the channels CS in the different elementary loops constituting the multiloop are different of necessity, which, for that matter, does not cause any routing difficulty of the signalling channel in the specified multiloop.
According to a preferred embodiment of the invention the units CII and RCIS are managed from control means constituted by a switch memory which allows to read the switch configurations of their switching matrix. For this purpose, each one of these two memories is written from an address bus and a data bus connected to a central microprocessor arranged in the superpilot. The switch memory for unit CII is read from a channel counter CI and the switch memory for unit RCIS from a channel counter CS, each configuration of interloop signalling switchings being spread in time over the period of time of a multiframe relative to the multiplexed signals of the different loops of the interloop configuration.
BRIEF DESCRIPTION OF THE DRAWING
The following description refers to the annexed drawings, given by way of example, to make it better understood how the invention can be realised therein:
FIG. 1a and 1b show the organisation of a time-division multiplexed signal, FIG. 1a showing the set of multiplexed signals and FIG. 1b the base frame,
FIG. 2 is a block diagram of a prior-art multiplex rearranging apparatus in a single loop,
FIGS. 3 and 4 are time diagrams showing at a the transmitted multiplexed signal and at b the received multiplexed signal, and which are used to explain the rearrangement of information and the rearrangement of the signalling respectively, for a single loop,
FIG. 5 shows a network of 4 loops which can be interconnected according to the invention in a central apparatus called superpilot,
FIG. 6 is the general block diagram of loop interconnecting apparatus according to the invention,
FIG. 7 shows the structure of a Synchronisation and Information Rearranging unit SRI,
FIG. 8 is the block diagram of the Interloop Information Switch CII,
FIG. 9 is the block diagram of the Interloop Signalling Switch RCIS which effects the rearrangement of the signals in the CS channels,
FIGS. 10 and 11 are the time diagrams which permit to explain the operations of the respective units CII and RCIS,
FIG. 12 shows a high-security multiloop network comprising three superpilots.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIGS. 1a and 1b show the organisation of a time-division multiplexed signal having two types of channel, that is, a fast and a slow rate channel.
As shown in FIG. 1b, the fast rate channels, which are intended in essence for the actual transmission of information (information channels CI) are constituted by time slots I1, I2, I3, . . . , I240 of a base frame TDB. In practice these time intervals each contain a bit whose duration is equal to 122 ns.
The slow rate channels (signalling channels CS) are each constituted by various separated time slots S, respectively situated each at the end of a base frame after the time slot I248. These time slots S each contain 8 bits referenced I249 to I256. Eight successive base frames constitute a slow rate channel frame, as shown in each line of FIG. 1a. The slow rate signalling channel CS1 is formed by the set of time slots S of the base frames TDB1 to TDB7; the channel CS2 is formed by the time slots S of the base frames TDB9 to TDB15, nd so on. The time slots S of the base frames TDB8, TDB16, . . . TDB2048, that is, the eight bits terminating each such frame, contain the frame code T used for defining the time intervals I1, I2, . . . , I240. The intervals S of the base frames TDB2041 to TDB2047, the last seven frames of the multiframe signal, contain the multiframe code T, the complement of code T, which permits to number the different frames to 256, the set of these frames constituting the multiframe of which the duration is for example, equal to 64 ms. The forming of each frame of a signalling channel CS thus requires a sequence of eight successive base frames as far as its periodicity is concerned. The multiframe comprises, among the 256 signalling channels CS, 240 channels (CS1, CS2, . . . , CS240) reserved for the users, corresponding with 240 information channels CI of each base frame (CI1, CI2, . . . , CI240). The bits 241 to 248 of each base frame are tone bits which do not play a particular role for this invention. Likewise, in order not to make this exposition too complex, the nature of the 15 channels having the same structure as the signalling channels CS, 241, . . . , 255 will not be explained here any further.
In order to simplify the comprehension of the multiloop communication system, several characteristic features of the time division multiplexed signal for each loop will be summed up hereinbelow:
______________________________________Bit rate of an information channel (fast rate): 32 kbits/sNumber of base-informational channels: 240Transmission rates available for the users (by 32, 64, 128,possibly grouping 2, 4, 8, 16 or 32 adjacent CIs: 256, 512 or 1024 kbits/sRepetition rate of the frame code T: 4000 /sLength of the frame code: 8 bitsMean bit rate of a signalling channel at 7 octets 875 bits/s(56 bits) per frameBit rate of the multiplexed signal: 8.192 MHzMultiframe period: 64 msFrame period: 250 μsBit period: 122 ns.______________________________________
If time-division multiplex is used (for example, the one described hereinbefore) in a looped telecommunication system, for example, comprising a single loop, it is necessary to rearrange the information by means of an information rearranging apparatus situated at a point in the loop. The system permits to exchange information between different connection circuits (concentrators) 2, 3, . . . , see FIG. 2, linked by a transmission line 10 (coaxial cable or optical fibre), which is looped back by means of a rearranging apparatus which at input terminal 12 receives the incoming multiplexed signal phase-shifted by several bits and produces at output terminal 11 the outgoing multiplexed signal rearranged by means of associated delay means which, as regards the incoming multiplexed signal, are different for the information channels CI and the signalling channels CS.
FIG. 2 shows by way of a diagram a prior-art rearranging apparatus 1 which permits to shift the multiplexed signal received over the transmission line 10 at the input terminal 12 in order to have it coincide with the channels of the multiplex signal to be transmitted at output terminal 11. A clock circuit 20 recovers the timing of the information signals appearing at terminal 12 and supplies its signals to a synchronisation circuit 21 which, while detecting the frame code T and multiframe code T, successively processes the signals so as to write them into a memory MEM for all the incoming multiplexed information signals. This memory has a data input EM connected to the input 12 and has an output SM. The memory MEM also receives a write command WM, an address bus AM and a read command RM.
In order to determine the timing of the outgoing multiplexed signal (transmission clocks), a clock signal generator 31 comprising a quartz oscillator is provided. This generator produces the addresses and the read command RM of the memory MEM. The read and write addresses are transported over the buses A21 and A31 respectively, coming from the respective circuits 21 and 31. These buses transmit a modulo-256 binary figure which figure evolves with the timing of the incoming or outgoing multiplexed signal. A switch CA controlled via the write wire WM of the memory MEM determines which of the address codes of the bus A21 or A31 is applied to the address bus of memory MEM.
To the output SM of memory MEM is connected a delay unit 35 which selects only the multiplexed signal bits contained in the time slots S and which delays these bits by 16320 times the average period during which the bits contained in the time slots S appear in the multiplexed signal, that is to say for the duration of 255 frames. A combination circuit (switch 40), when in the position represented in the Figure, enables transmission of at least the information of the channels CI of the output multiplexed signal at terminal 11, the latter then being directly connected to the output SM. When the switch 40 has assumed the other positions, it enables transmission of the information of the signalling channels CS, plus the codes T and T, in the multiplexed signal since the terminal 11 is then connected to the output of the delay unit 35. The operating sequence of the switch 40 is controlled over by means of a conductor 41 transporting a clock signal coming from the transmission clock generator 31. What has just been described permits to effect in a known manner two types of rearrangement for the loop 10, as explained with reference to the FIGS. 3 and 4,
the rearrangement of information signals, which are fast signals,
the arrangement of signalling signals which are slower signals.
The FIGS. 3 and 4 show at a the transmitted multiplexed signals and b the received multiplexed signals.
The rearrangement of information signals, see FIG. 3, consists of repositioning the received information bits to their precise ranks in the transmission base frames. In FIG. 3 the 8 base frames are referenced 0 to 7. The transmission delay is referenced RT. In order to take into account that there may be a large number of concentrators in the loop 10, the rearrangement is realised over 8 base frames, that is, one signalling frame. This implies that the maximum permissible delay for the loop is 2048 bits, or 250 μs. Whatever the transit time of the multiplexed signals in the loop, within the aforesaid maximum, in this way the rearranging apparatus 1 automatically shifts the information bits received over the transmission channels CE in accordance with the next 8 base frames. This fact normalises a fixed information transmission delay for the entire loop, including the passage through the rearranging apparatus 1. Referring again to FIG. 2, it will be noticed that the memory MEM, owing to its storing capacity and its read/write sequence, operates to normalise tis delay to the fixed value of 8 base frames for the time-division multiplexed signals throughout the loop.
The rearrangement of the signalling signals (distributed slow-rate time slots S per octet of base frames), see FIG. 4, permits to take off, by means of the delay unit 35, the contents of the signalling channels CS of the multiplexed signal received by the rearranging apparatus 1, so as to place them back with the same rank into the next multiframe of the transmitted multiplexed signal. Hereinbefore it has been shown that the rearranging of the information signals permits to rearrange the entire received multiplexed signal by a constant amount equal to the duration of one frame, or one signalling channel.
With respect thereto, the rearrangement of all the received signalling channels is effected by delaying to the octets concerned by a systematic delay which is equivalent to the duration of: 256-1=255 frames, or the duration of 255 CS channels at the end of the rearrangement of the information, so that the contents of these channels are repositioned in channels having the same rank in the next multiframe. The overall delay caused by this operation is also constant and equal to 64 ms over the whole loop, including the time for passage through rearranging apparatus 1. It is the delay means 35, see FIG. 2, which effects the rearranging of the signalling signals; it comprises (in a manner not shown) an eight-bit shift register whose input is connected to the output SM and whose output is connected to the data input of a memory device comprising 16312 one-bit words; the addresses of this memory are produced by a modulo-16312 counter. The output of the memory is connected to the input of an eight-bit shift register whose output is connected to a second input terminal of the switch 40. A control highway CO from circuit 31 commands with the appropriate sequences, over each of the 4 conductors, each of the four aforesaid elements, within the delay unit 35 in order to adapt the binary rates of the channels CS between the multiplex and the memory. For more details about the single loop system described hereinbefore, the reader be referred to French Patent Specification 2 526 614 mentioned above, incorporated as a reference in this description.
The present invention permits to enhance appreciably the capacity of the system by adopting a system having a plurality of loops, whilst these loops can remain independent and identical with the loop described hereinbefore as regards the mode of operation and technology used, and interconnected in any desirable way so that among other things a given user in the system can communicate with any other user.
In order to interconnect the loops, at least a single central unit called a superpilot is provided through which each of the loops pass.
In order to improve the security of the system various identical superpilots can be provided, of which only one is active at any time, whilst the others have stand-by status and are thus transparent to the multiplexed signals passing through.
The system in FIG. 5 has 4 loops B1, B2, B3, B4 which are similar to the loop of FIG. 2. Each loop comprises a certain number of concentrators referenced 45, which number may be several dozen. In a detectable predetermined direction, over the input and output terminals, each loop passes through a central unit 46 called a superpilot which comprises the apparatus according to the invention for rearranging information. The input and output terminals E1 and S1 respectively, of the loop B1, for example, correspond to the input and output terminals 12 and 11 respectively, of the loop in FIG. 2.
A block diagram of the information rearranging apparatus for various loops, contained in the superpilot 46, is shown in FIG. 6. Therein the inputs E1, E2, E3, E4 and the outputs S1, S2, S3 and S4 are those in four loops of the FIG. 5. Each such input is connected to an apparatus for rearranging the information channels CI of the incoming signals and for synchronisation, SRI1, SRI2, SRI3, SRI4, which is to establish a delay of one frame, which is 250 μs, between the outgoing multiplexed signal produced at outputs S1, S2, S3, S4 and the corresponding output terminal F1, F2, F3, F4 of each SRI (outputs F). It should be observed that the time division multiplexed signals of the different loops are identical and, for example, such as described with reference to the FIGS. 1a and 1b. Also, the multiplexed signals at S1, S2, S3, S4 are synchronous and, consequently also synchronous with F1, F2, F3, F4, which is a necessity, for using the invention even when there is asynchronism of the incoming time-division multiplexed signals at the inputs E1 to E4. A block diagram of an SRI apparatus for rearranging and synchronisation signals of the CI channel is described hereinbelow with reference to FIG. 7. For example, each SRI is that which is described with reference to the left portion of FIG. 2 (elements 20, 21, 31, CA and MEM). In order to save storage capacity the SRI structure of SRI may alternatively be as described with reference to the left part of FIG. 3 of aforesaid French Patent Specification 2 526 614 which part is located between terminal 12 and the output SM therein. That structure, which saves storage capacity, is characterized in that the set of memories equivalent to the memory MEM of FIG. 2 of this application is formed by n (n>1) memories whose individual capacities are sufficiently large to contain a frame whilst the number of frames forming a multiframe exceed n, and in that means are provided for avoiding the same memory being addressed simultaneously by the read and write circuits.
Each SRI receives from a transmission timing generator GRE 50 (FIG. 6) and a generator 51 of frame code T and multiframe code T, GT/T comprising a quartz oscillator, the signals necessary for its operation. These signals are provided over a multiple conductor 52 which accommodates between 25 and 30 conductors, and may be considered clock signals. The SRI output terminals F1, F2, F3, F4 are connected to as many inputs of a unit CII and also to as many inputs of a unit RCIS. CII is an Interloop Information Switching unit. It does not cause any delay in the signals passing through; it is constituted in essence by a square switching matrix, in this case having 4 rows and 4 columns, thus 16 intersections comprising each a switch, and it is used to realise all the desired interconnections between loops for the information channels CI, channel-by-channel. Unit CII will be described hereinbelow with reference to FIG. 8; its outputs I1, I2, I3, I4 are connected to the first terminals of the combination circuits in this case two-way switches 61, 62, 63, 64 whose common terminals are connected to the respective outputs S1, S2, S3, S4 and which are controlled from the multiple conductor 52.
RCIS is an apparatus for Rearranging and Interloop Switching of the CS channel signals. Its twofold function is to rearrange the signalling channels CS of the incoming multiplexed signals into the outgoing multiplexed signals and also to realise all the interconnections desired between loops for the signalling channels CS. It should be observed that in general a signalling channel is assigned to an information channel, their respective serial numbers are not the same of necessity but in tis case the interloop interconnections realised for the information channel and the signalling channels are the same, that is to say, the same elementary loops forming the multiloop are passed through the channels CI and CS, but these configurations are spread in time with a periodicity and a form factor which are different. The unit RCIS, which constitutes the main item of the invention, comprises a set of delay units associated to a switching matrix, preferably of 4 rows and 16 columns, that is, 64 intersections comprising each a switch. The unit RCIS will be described hereinbelow with reference to FIG. 9; its outputs J1, J2, J3, J4 are connected to the respective second terminals of the switches 61, 62, 63, 64 whose switching sequences for transmitting an information channel bit or a signalling channel bit or octet are controlled from the transmission timing control bus 52.
Preferably, the open-close commands for the switches in the units CII and RCIS are provided in a simple way by data processing means 70 represented diagrammatically in FIG. 6. This is a μp or microprocessor, for example of the 68000 type manufactured by the American MOTOROLA company. The data bus BD and the address bus BA of the microprocessor are connected to the units CII and RCIS. There is also an information channel counter CCI, 71, controlled over via the conductor 52, and whose output bus BRI is connected to the unit CII. A signalling channel counter CCS, 72, also controlled via the conductor 52, has an output bus BRS connected to the unit RCIS.
In FIG. 7 is shown a block diagram an input unit SRI of the rearranging apparatus. This unit effects the rearrangement of all the multiplexed information signals of the loop passing through the unit and more specifically, the rearrangement of the channels CI by forming between the outputs S1, S2, S3, S4 of the apparatus and the output F of the SRI concerned a delay which is equal to a CS channel frame period, which is 8 base frames of the CI channel. The unit SRI comprises an information memory 80 receiving via buffer elements 81 and 82 the data of a time-division multiplexed signal of an elementary loop at its input E and the signals from the multiple conductor 52 constituting the transmission clocks and used for effecting the synchronisation already described hereinbefore. In order to bring the received data in phase again with the transmission time base, the memory 80, constituted by RAM modules, temporarily stores for each base frame in succession the received multiplexed signal before returning it in phase with the transmission clocks. This memory is thus addressed in the write mode by the clocks of the receive time base and addressed in the read mode by the clocks of the transmit time base. Preferably, in order to bring about an agreement between the time diagram of the received multiplexed signal and the time of the access to the memories, it is advantageous to demultiplex in pairs in a demultiplexer 83 the bits received at E so as to store two bits at each memory address. A multiplexing circuit 84 connected to the output of memory 80, controlled by the signals over the conductor 52, then arranges the outgoing bits of the memory 80 and thus produces at its output the rearranged information signal at terminal F. Each circuit SRI behaves as a delay line providing always the same frame transit time, that being 8 base frames (t 10 =250 μs), in each loop whatever the amount of equipment (variable) inserted into the loop it controls.
In FIG. 8, the information channel interloop switch CII is constituted in essence by a first switching matrix 85 and by a first switching memory 86. The columns of the matrix 85 are connected with the terminals F1, F2, F3, F4 and the rows with the outputs I1, I2, I3, I4 of the unit CII. At each intersection of the matrix a switch 87 is symbolised, each switch enabling the connection or the disconnection of a column line and a row line. A switch configuration between loops is realised when one switch per line and one switch per loop is closed. The closing times of the switches for a given configuration are spread in accordance with the delays caused by the units SRI inserted into the multiloop under discussion. These configurations are obtained on the basis of memory 86 activated in the read mode, the closing time of each interruptor being that of a CI, that is to say, one bit. The memory 86 contains at least 240 locations each one of which may contain several bits representing a switch configuration of the matrix; this memory is dynamically written from the two-way data bus BD coming from the microprocessor 70, and is addressed in the write mode via a random access over the address bus BA. The memory 86 is read at each clock bit period by means of clocking from bus BRI coming from the information channel counter CCI. Over a single bus 89 a priority logic circuit 88 makes the access of bus BA and that of BRI compatible to the memory 86. The memory 86 preferably comprises 256 words of 16 bits; for each of the 4 receive loops a 4-bit code determines one of the 4 information signals to be switched which have been rearranged at F.
The switching operation of the multiloop information channels takes place in the following manner: a multiloop information channel is identified by the occupation of an information channel CI in each of the multiplexed signals of the loops it interconnects, as illustrated in FIG. 10. The transmission of information signals through 2, 3 or 4 loops for a given channel is realised by means of real-time transfer from one loop to the other of data transmitted in the timing paths assigned to this channel. The rank of the information channels CI used in each multiplex for supporting the multiloop information channel is the same in the multiplexed loops concerned. The duration of the interconnection (one or various adjacent CI channels) and the number of the channel used are determined by the software (microprocessor 70). The transit time of the information signals travelling in the interconnected loops is a multiple of the transit time t 10 of one loop, that is 500 μs for two loops, 750 μs for three loops and 1 ms for 4 loops.
FIG. 10 shows examples of multiloop information channels. An activation of the first control means (86, 87, 88, BD, BA, BRI) causing the desired interconnection between 2 (ITb), 3 (ITc) or 4 (ITa) loops by successively closing the respective switches corresponds with each time interval IT (a, b, c) representing a multiloop channel in the base frame (TO).
The unit RCIS shown in FIG. 9 for rearranging the interloop switching the signalling channels CS comprises in essence delay units 90, a second switching matrix 91 and a second switching memory 92. The memory 92 belongs to control means which are analogous to the control means prepared for the unit CII: this memory is also written from the data bus BD with a random access address by the bus BA, via a priority logic circuit 93. Reading the memory is effected by means of clocking, from bus BRS coming from the signalling channel counter CCS and connected to memory 92, with a timing of channel periods CS. Each switching configuration 91 is maintained as regards the closing of each interruptor of the configuration for the duration of one channel CS, that is to say: either during the whole period of 7 successive base frames which do not contain the final synchronisation octet T, or during the periods S of the final octets of these 7 base frames.
Each input F1, F2, F3, F4 of the unit RCIS is connected to a transmission line comprising as many delay units 90 as there are loops, in this case 4. The output of each delay unit is connected to a column of the matrix 91 of which each line is connected to an output J1, J2, J3 and J4 of the unit RCIS, preferably through an 8-bit shift register 95. At each intersection of the matrix is symbolised a switch 96, each switch permitting to connect or disconnect a column line and a row line. The matrix 91 comprises 64 switches and, more generally 2 3 switches for P elementary loops. The memory 92 is organised, for example, in 256 words of 16 bits. An interloop switching configuration for the signalling is realised when one switch per line, a single one that is, is closed during the separate time intervals with can be compared with the signalling information passing through the loops to be interconnected. Alternatively, each loop interconnection is effected by means of the software so that a multiple loop over its entire length passes through 4(p), that is, only 4(p), delay means 90 while each of these units 90 cause a delay which is equal to a quarter of the duration of the multiframe (16 ms), which is also the average duration of 4096 signalling bits (including the bits of the code T and T). It should be observed that each input delay line, on the left in FIG. 9, causes a delay of 4024 bits, taking the fact into account that it is advisable to add to this delay the delay of 8 bits caused by an input shift register 97, and a delay (8 signalling or code T/T bytes) caused by the unit SRI arranged upstream. The signalling bytes contained in the rearranged signals of the 4 loops at F1-F4, are also delayed by approximately 64 ms by the delay lines 90 comprising intermediate taps having delays of 16 ms (t 11 ), 32 ms (t 12 ) and 48 ms (t 13 ), see FIG. 11. These delay lines are realised, for example, with RAM memory modules. The switching matrix 91 switches for each signalling channel the signalling octets from one of the 16 possible delay line outputs to the outgoing multiplexed signals of the 4 loops. A 16-bit-wide word of the matrix 92 corresponds with each switch configuration. This word is divided into 4 times 4 bits, each 4 bit-wide code determining for each of the 4 lines of the matrix, one of the 16 outputs of the delay lines to be switched.
The switching operation of the multiloop signalling channels CS takes place in the following manner: a multiloop channel is identified by the occupation of a signalling timing channel (channel CS) in each of the multiplex signals of the loops it interconnects. The transmission of signalling signals through 2, 3 or 4 loops, for a given channel is realised by real-time transfer from one loop to the next of data transmitted through the timing paths assigned to this channel, as this appears from FIG. 11 in which it will be observed that the ranks of the channels CS in the multiframes of the different loops are different of necessity. The duration of the interconnection and the rank of the channel used in each multiplexing are determined by the software used. Obtaining a propagation time of a multiloop signalling channel which is identical with that of a single loop signalling channel is effected by the particular structure and operation of the unit RCIS described above. Each switching configuration is established by the software on the basis of different parameters specifying the loops to be interconnected and the points of the delay lines 90 to be switched for each of the multiloop channels concerned. As has already been indicated hereinbefore, the switches of the multiloop channels are established in a manner such that the total of the transit times in each part of the lines which have been passed through is always equal to the period Tm of a multiframe (64 ms). The switching matrix 91 then permits to create multiloop channels which are independent and may serve the 2, 3 or 4 loops simultaneously. The multiloop signalling channels then have an access time which is identical with that of the single loop channels and can be used for controlling the communication between two users belonging to two different loops or more than two users in case of teleconferencing, for example, which may imply more than two loops.
FIG. 11 shows three signalling channel CS switching configurations. The letters q, c and d symbolise an integer which indicates the rank of a signalling channel CS in a loop multiplex. It should be recalled for that matter that the periods t 11 , t 12 and t 13 are equal to 16 ms, 32 ms, 48 ms respectively. When reading the rows L of the matrix 91 from top to bottom and the columns C from left to right, the configuration referenced q interconnecting the 4 loops implies the successive closing in steps of 16 ms of the switches L2-C4, L3-C3, L4-C2, L1-C1. The configuration c for three loops implies the successive closing of the switches L4-C2, L3-C3, L2-C5. The configuration d for two loops B1 and B2 implies the successive closing in alternate steps of 16 ms and 48 ms of the switches L2-C4, L1-C11.
The choice of management techniques of the multiloop channels is connected with the specifications as regards channel assignment as a function of their embodiments which themselves depend on different services to be rendered for a given system. These specifications are to specify, for example:
the number of dedicated channels (to an application)
the number of affected channels (dynamically or not)
the number of channels and pools and the number of pools (teleconferences).
In the case of dedicated channels the superpilot 46 (see FIG. 12) causes the interloop switchings to be effected by means of a microprocessor 70 (see FIG. 6) once the system is initiated, which permits to dispose of permanent multiloop channels. If the channels are managed as a pool, the request for a multiloop channel which is addressed to the superpilot through a concentrator is to contain information specifying the loops to be interconnected. It is on the basis of this information that the superpilot finds the available channels in the pool of the multiplex channels concerned which have the characteristic features necessary for the interconnection; this constitutes the dynamic allocation of the channels CI and CS. When the channels requested have been found, the superpilot performs the interloop switchings which permit to use the necessary multiloop information and signalling channels and answers back to the requesting concentrator. Then this concentrator receives from the superpilot the numbers of the multiloop channels which are assigned thereto for the duration of the interloop communication. Alternatively, at the end of the communication, these channels are freed by the superpilot which performs the corresponding switchings. The software processing of the interloop switchings for the channels CI and CS then permits a dynamic and very smooth two-way signalling for establishing communications in the network.
FIG. 12 shows the architecture of the system concentrating around 3 superpilot units 46 (SP1, SP2, SP3) which permit to interconnect 2 to 4 loops, in this case 3 loops comprising each up to 62 concentrators. Each loop of necessity passes through the 3 common nodes constituted by the 3 superpilot units owing to which the exchange of information between the loops is possible. The concentrator equipment 45 inserted into the loops is arranged in cascade by identical transmission supports which ensure the necessary digital links. Each user of the system is connected to at least one of these concentrators and communicates via one or various loops with the other users, as a function of their distribution in the network. The signals transmitted through the loops are preferably biphase encoded signals which permits to transmit only a single signal and to use without discrimination coaxial cable or optical fibre as transmission loop supports. With respect to this matter it should be observed that these transmission supports are doubled for each loop, according to FIG. 12, in order to augment the operation security. Actually, the latter arrangement permits when seizing loops partly (one information support) or completely (the two information supports), to realise loop configurations automatically by means of an active superpilot. The superpilot units ensure all the time division switching operations which permit to exchange signalling messages and to establish full duplex or half duplex information links in a single loop or between various loops. Special links 98 connect the 3 superpilots; they permit to establish outside the loops a direct dialogue between these three units one of which is normally active whereas the two other units are stand-by and ready to relay automatically one or the other if the active superpilot breaks down.
From a point of view of technology the switching matrices 85 and 91 may be realised in the following manner, for example, on the basis of integrated circuit components manufactured by the American company of FAIRCHILD
for the input and output interfaces of the matrices (columns, rows, connecting buses to the switching memory): D-flipflops of the F175 type
for realising switches on the basis of one closed switch per row (1 in 4 or 1 in 16): two-step combination of NAND gate circuits, F00 and F20.
If one wishes to enhance the capacity of the communication network described hereinbefore even more, two further possibilities are within the scope of the invention.
The number of loops may be augmented by bringing the number from 4 to 8 for example (adopting a multiple of 2 for the number of loops is to be preferred, which simplifies the manufacture and operation of the delay units 90). In this case the same multiplex as that described hereinbefore is retained as regards its structure and its rate.
Alternatively, while retaining, for example, 4 loops, the multiplex rate may be doubled bringing it to 64 kbits/s instead of 32 kbits/s, which then presents the additional advantage of being able to transmit the MIC encoded digital information in more than the differential encoding Δ, only used at 32 kbits/s.
It should also be observed that, in addition to communications between users as shown by single-loop or multiloop configurations, it is also possible according to the invention to broadcast from the user station to any other user stations. | Apparatus for rearranging signal channels of a multi-loop TDM transmission system, each loop having a plurality of high rate channels CI in successive base frames, portions of successive base frames forming a plurality of low rate channels CS. The system capacity can thereby readily be expanded by including additional loops. In order to rearrange a plurality p of asynchronous TDM signals into the correct channels to constitute a plurality of synchronous outgoing TDM signals, the apparatus includes respective units SRI for providing synchronization and rearrangement of the signals in the high rate (CI) channels. The p outputs of the SRI units are connected to p respective inputs of an interloop switching unit CII for switching the CI channels, and also to p respective inputs of an interloop switching unit RCIS which rearranges and switches the CS channels. The p outputs of the unit CII and the p outputs of the unit RCIS are paired, the respective pairs being supplied to respective combination circuits which combine the signals in each pair to derive the respective synchronous multiplexed outgoing signals. | 7 |
[0001] This is a divisional of application Ser. No. 11/190,081 filed Jul. 25, 2005, currently pending.
BACKGROUND OF THE INVENTION
[0002] This invention relates to agents for the processing of synthetic fibers and methods of processing synthetic fibers.
[0003] The production speed of synthetic fibers is increasing rapidly in recent years. At the same time, there is a tendency to increase the production of new kinds of synthetic fibers such as low denier synthetic fibers, high multifilament synthetic fibers and modified cross-section synthetic fibers. If synthetic fibers of such new types are produced at a higher speed, their friction increases with the yarn passing, guides, rollers and heater. This causes an increase in the friction-charged electrostatic potential, resulting in low cohesion and unwanted tension variations of synthetic fibers, and the problems of fluffs and yarn breaking tend to occur. The present invention relates to agents for and methods of processing synthetic fibers capable of sufficiently preventing the occurrence of fluffs and yarn breaking as well as dyeing specks even when synthetic fibers of the aforementioned new kinds are produced at an increased production rate.
[0004] Examples of prior art processing agent for synthetic fibers for preventing the occurrence of fluffs and yarn breaking at the time of their high rate of production include (1) processing agents for synthetic fibers containing polyether compounds with molecular weight of 1000-20000, having dialkylamine with random or block addition of alkylene oxide with 2-4 carbon atoms (such as disclosed in Japanese Patent Publication Tokkai 6-228885); (2) processing agents for synthetic fibers containing branched-chain polypropylene glycol having 4 or more branched chains (such as disclosed in Japanese Patent Publication Tokkai 10-273876); (3) processing agents for synthetic fibers containing a polyether lubricant having 10-50 weight % of polyether block of number average molecular weight of 1000-10000 with block copolymerization of ethylene oxide and propylene oxide at weight ratio of 80/20-20/80 (such as disclosed in Japanese Patent Publication Tokkai 2001-146683); and (4) processing agents for synthetic fibers containing polyoxyalkylene glycol with number average molecular weight of 5000-7000 with copolymerization of ethylene oxide and propylene oxide at weight ratio of 40/60-20/80, monocarboxylic acid with 8-14 carbon atoms and alkylamine salt with 6-14 carbon atoms or quaternary ammonium salt (such as disclosed in Japanese Patent Publication Tokkai 10-245729).
[0005] These prior art processing agents are not sufficiently capable of preventing the occurrence of fluffs, yarn breaking and dyeing specks when synthetic fibers are produced at a fast rate and in particular when synthetic fibers of the aforementioned new kinds are produced at a fast rate.
SUMMARY OF THE INVENTION
[0006] It is therefore an object of this invention to provide a processing agent and a process method capable of sufficiently prevent the occurrence of fluffs, yarn breaking and dyeing specks even when new kinds of synthetic fibers such as low denier synthetic fibers, high multifilament fibers and modified cross-section synthetic fibers are produced at a fast rate
[0007] The present invention is based on the discovery by the present inventor, as a result of his studies in view of the object described above, that a processing agent containing hydroxy compound of a specified kind at least as a part of functional improvement agent at a specified rate should be applied to the synthetic fibers.
DETAILED DESCRIPTION OF THE INVENTION
[0008] The invention firstly relates to a processing agent for synthetic fibers characterized as containing a lubricant and a functional improvement agent and containing hydroxy compound as described below in an amount of 1-30 weight % at least as a part of the functional improvement agent. The invention secondly relates to a processing method for synthetic fibers characterized as comprising the step of applying a processing agent of this invention to synthetic fibers so as to be 0.1-3 weight % with respect to the synthetic fibers. In the above, hydroxy compound is one or more selected from the group consisting of compounds shown by Formula 1 and the group consisting of compounds shown by Formula 2 where Formula 1 is:
[0000]
and Formula 2 is:
[0009]
[0000] where R 1 , R 2 , R 3 and R 4 are each hydrogen atom or aliphatic hydrocarbon group with 1-12 carbon atoms (only two or less of them being hydrogen atom at the same time); R 7 , R 8 , R 9 and R 10 are each hydrogen atom or aliphatic hydrocarbon group with 1-12 carbon atoms (only two or less of them being hydrogen atom at the same time); R 5 , R 6 , R 11 and R 12 are each hydrogen atom, methyl group or acyl group with 1-3 carbon atoms; and A 1 and A 2 are each residual group obtainable by removing hydrogen atoms from all hydroxyl groups of (poly)alkyleneglycol having (poly)oxyalkylene group formed with a total of 1-30 oxyalkylene units with 2-4 carbon atoms.
[0010] Processing agents for synthetic fibers according to this invention (hereinafter referred to simply as processing agents of this invention) will be described first.
[0011] Processing agents of this invention are characterized as containing a lubricant and a functional improvement agent and containing hydroxy compound of a specified kind at least as a part of the functional improvement agent.
[0012] What is herein referred to as hydroxy compound of a specified kind is one or more selected from the group consisting of compounds shown by Formula 1 and the group consisting of compounds shown by Formula 2.
[0013] Regarding Formula 1, R 1 , R 2 , R 3 and R 4 are each hydrogen atom or aliphatic hydrocarbon group with 1-12 carbon atoms but only two or less of them may be both hydrogen atom. Thus, there are (1) examples where two of them are each aliphatic hydrocarbon group with 1-12 carbon atoms, the remaining two being each hydrogen atom; (2) examples where three of them are each aliphatic hydrocarbon group with 1-12 carbon atoms, the remaining one being hydrogen atom; and (3) examples where each of them is aliphatic hydrocarbon group with 1-12 carbon atoms. Among these examples, the examples in (1) are preferred. Examples of aliphatic hydrocarbon group with 1-12 carbon atoms in (1)-(3) include methyl group, ethyl group, butyl group, hexyl group, heptyl group, octyl group, nonyl group, decyl group, undecyl group, dodecyl group, isopropyl group, t-butyl group, isobutyl group, 2-methylpentyl group, 2-ethyl-hexyl group, 2-propyl-heptyl group, 2-butyl-octyl group, vinyl group, allyl group, hexenyl group and 10-undecenyl group. Among these, aliphatic hydrocarbon groups with 1-6 carbon atoms are preferable and those for which the total number of carbon atoms for R 1 -R 4 is 2-14 are particularly preferable. R 5 and R 6 are each (1) hydrogen atom, (2) methyl group or (3) acyl group with 1-3 carbon atoms such as formyl group, acetyl group or propyonyl group. Among these, however, hydrogen atom is preferred.
[0014] The hydroxy compounds shown by Formula 1 themselves can be synthesized by a conventional method such as disclosed in Japanese Patent Publication Tokkai 2002-356451.
[0015] Regarding compounds shown by Formula 2, R 7 -R 10 are the same as described above regarding R 1 -R 4 , and R 11 and R 12 are the same as described above regarding R 5 and R 6 . A 1 and A 2 are each residual group obtainable by removing hydrogen atoms from all hydroxyl groups of (poly)alkyleneglycol having (poly)oxyalkylene group formed with a total of 1-30 oxyalkylene units with 2-4 carbon atoms. Examples of what A 1 and A 2 may each be include (1) residual groups obtainable by removing hydrogen atoms from all hydroxyl groups of alkyleneglycol having oxyalkylene unit formed with one oxyalkylene unit with 2-4 carbon atoms and (2) residual groups obtainable by removing hydrogen atoms from all hydroxyl groups of polyalkyleneglycol having polyoxyalkylene group formed with a total of 2-30 oxyalkylene units with 2-4 carbon atoms, and examples of oxyalkylene unit with 2-4 carbon atoms forming such polyoxyalkylene group include oxyethylene unit, oxypropylene unit and oxybutylene unit. Among these, residual group obtainable by removing hydrogen atoms from all hydroxyl groups of ethyleneglycol, residual group obtainable by removing hydrogen atoms from all hydroxyl groups of propyleneglycol and residual group obtainable by removing hydrogen atoms from all hydroxyl groups of polyalkyleneglycol having polyoxyalkylene group formed with a total of 2-12 oxyethylene units and oxypropylene units are preferable. If the polyalkylene group is formed with two or more different oxyalkylene units, their connection may be random connection, block connection or random-block connection.
[0016] The hydroxy compounds shown by Formula 2, as explained above, themselves can be synthesized by a conventional method such as disclosed in Japanese Patent Publication Tokkai 3-163038.
[0017] Processing agents of this invention are characterized as containing a lubricant and a functional improvement agent and containing one or more of hydroxy compounds selected from the group of compounds shown by Formula 1 and the group of compounds shown by Formula 2 as described above in an amount of 1-30 weight % at least as a part of the functional improvement agent but those containing such hydroxy compounds in an amount of 2-25 weight % are preferable and those containing such hydroxy compounds in an amount of 5-20 weight % are even more preferable.
[0018] Processing agents of this invention may contain functional improvement agents other than the hydroxy compounds shown by Formula 1 and Formula 2. Examples of such other functional improvement agent include those conventionally known kinds such as (1) antistatic agents including anionic surfactants such as organic sulfonic acid salts and organic aliphanic acid salts, cationic surfactants such as lauryl trimethyl ammonium sulfate, and ampholytic surfactants such as octyl dimethyl ammonioacetate; (2) oiliness improvement agents such as organic phosphoric acid salts and aliphatic acid salts; (3) penetration improvement agents such as polyether modified silicone having polydimethyl siloxane chain with average molecular weight of 1500-3000 as main chain and polyoxyalkylene chain with average molecular weight of 700-5000 as side chain and surfactant having perfluoroalkyl group; (4) cohesion improvement agents such as polyetherpolyesters; (5) extreme-pressure additives such as organic titanium compounds and organic phosphor compounds; (6) antioxidants such as phenol antioxidants, phosphite antioxidants and thioether antioxidants; and (7) antirust agents.
[0019] When a processing agent of this invention contains such other functional improvement agents, their content should preferably be 0.2-15 weight % and more preferably 1-12 weight %.
[0020] Processing agents of this invention contain a lubricant and a functional improvement agent as explained above. Examples of such lubricant include conventionally known kinds such as (1) polyether compounds; (2) aliphatic ester compounds; (3) aromatic ester compounds; (4) (poly)etherester compounds; (5) mineral oils; and (6) silicone oils.
[0021] Examples of aforementioned polyether compound include polyether monool, polyether diol and polyether triol, all having polyoxyalkylene group in the molecule. Among these, however, polyether compounds with average molecular weight of 700-10000 are preferred and polyether compounds with average molecular weight of 700-10000 with monohydric-trihydric hydroxy compound with 1-18 carbon atoms having block or random attachment of alkylene oxide with 2-4 carbon atoms are particularly preferable.
[0022] Examples of aforementioned aliphatic ester compound include (1) ester compounds obtainable by esterification of aliphatic monohydric alcohol and aliphatic monocarboxylic acid such as butyl stearate, octyl stearate, oleyl stearate, oleyl oleate and isopentacosanyl isostearate; (2) ester compounds obtainable by esterification of aliphatic polyhydric alcohol and aliphatic monocarboxylic acid such as 1,6-hexanediol didecanoate and trimethylol propane monooleate monolaurate; and (3) ester compounds obtainable by esterification of aliphatic monohydric alcohol and aliphatic polycarboxylic acid such as dilauryl adipate and dioleyl azelate. Among these, however, aliphatic ester compounds with 17-60 carbon atoms are preferable and aliphatic ester compounds with 17-60 carbon atoms obtainable by esterification of aliphatic monohydric alcohol and aliphatic monocarboxylic acid or aliphatic polyhydric alcohol and aliphatic monocarboxylic acid are particularly preferable.
[0023] Examples of aforementioned aromatic ester compound include (1) ester compounds obtainable by esterification of aromatic alcohol and aliphatic monocarboxylic acid such as benzyl stearate and benzyl laureate; and (2) ester compounds obtainable by esterification of aliphatic monohydric alcohol and aromatic carboxylic acid such as diisostearyl isophthalate and trioctyl trimellitate. Among these, however, ester compounds obtainable by esterification of aliphatic monohydric alcohol and aromatic carboxylic acid are preferable.
[0024] Examples of aforementioned (poly)etherester compound include (1) (poly)etherester compounds obtainable by esterification of (poly)ether compound obtainable by adding alkylene oxide with 2-4 carbon atoms to monohydric-trihydric aliphatic alcohol with 4-26 carbon atoms and aliphatic carboxylic acid with 4-26 carbon atoms; (2) (poly)etherester compounds obtainable by esterification of (poly)ether compound obtainable by adding alkylene oxide with 2-4 carbon atoms to monohydric-trihydric aromatic alcohol and aliphatic carboxylic acid with 4-26 carbon atoms; and (3) (poly)etherester compounds obtainable by esterification of (poly)ether compound obtainable by adding alkylene oxide with 2-4 carbon atoms to aliphatic alcohol with 4-26 carbon atoms and aromatic carboxylic acid.
[0025] Examples of aforementioned mineral oil include mineral oils of various kinds having different viscosity values. Among these, however, those with viscosity 1×10 −6 -1.3×10 −1 m 2 /s at 30° C. are preferable and those with viscosity 1×10 −6 -5×10 m 2 /s are even more preferable. Examples of such preferable mineral oil include fluid paraffin oil.
[0026] Examples of aforementioned silicone oil include silicone oils of various kinds having different viscosity values. Among these, however, linear polyorganosiloxane with viscosity 1×10 −3 -1 m 2 /s at 30° C. is preferable. Examples of such linear polyorganosiloxane include linear polydimethylsiloxane without substituent and linear polydimethylsiloxane with substituent, all with viscosity 1×10 −3 -1 m 2 /s at 30° C. Examples of substituent in these cases include ethyl group, phenyl group, fluoropropyl group, aminopropyl group, carboxyoctyl group, polyoxyethylene oxypropyl group and ω-methoxy polyethoxypolypropoxy propyl group. Among these, linear polydimethylsiloxane without substituent is preferable.
[0027] Among processing agents of this invention, those containing a lubricant as described above in an amount of 50-90 weight % and a functional improvement agent as described above in an amount of 1-30 weight % are preferable. Those further containing a hydroxy compound shown by Formula 1 or Formula 2 as described above in an amount of 1-30 weight % as the functional improvement agent are even more preferable.
[0028] Processing agents of this invention may further contain an emulsifier. An emulsifier of a known kind may be used. Examples of emulsifier of a known kind that may be used for the purpose of this invention include (1) nonionic surfactants having polyoxyalkylene group in the molecule such as polyoxyalkylene alkylethers, polyoxyalkylene alkylphenylethers, polyoxyalkylene alkylesters, alkylene oxide adducts of castor oil and polyoxyalkylene alkylaminoethers; (2) partial esters of polyhydric alcohol type nonionic surfactants such as sorbitan monolaurate, sorbitan trioleate, glycerol monolaurate and diglycerol dilaurate; and (3) partial esters of polyhydric alcohol type nonionic surfactants such as alkylene oxide adducts of partial esters of trihydric-hexahydric alcohol and aliphatic acid and partial or complete esters of alkylene oxide adduct of trihydric-hexahydric alcohol and aliphatic acid. Among these, however, polyoxyalkylenealkylethers having polyoxyalkylene group with 3-10 oxyethylene units and alkyl group with 8-18 carbon atoms in the molecule are preferable.
[0029] If processing agents of this invention contain an emulsifier as described above, it is preferable that such an emulsifier be contained in an amount of 2-30 weight %.
[0030] Among the processing agents of this invention containing an emulsifier, those containing a lubricant in an amount of 50-90 weight %, a functional improvement agent in an amount of 1-30 weight % and an emulsifier in an amount of 2-30 weight % (with a total of 100 weight %) are preferable. Those containing a hydroxy compound shown by Formula 1 or Formula 2 as described above in an amount of 3-25 weight % at least as a part of this functional improvement agent are even more preferable.
[0031] Next, the method according to this invention for processing synthetic fibers (hereinafter referred to simply as the method of this invention) is explained. The method of this invention is a method of applying a processing agent of this invention as described above at a rate of 0.1-3 weight % and more preferably 0.3-1.2 weight % of the synthetic fibers to be processed. The fabrication step during which a processing agent of this invention is to be applied to the synthetic fibers may be the spinning step or the step during which spinning and drawing are carried out simultaneously. Examples of the method of causing a processing agent of this invention to be attached to the synthetic fibers include the roller oiling method, the guide oiling method using a measuring pump, the emersion oiling method and the spray oiling method. The form in which a processing agent of this invention may be applied to synthetic fibers may be as a neat, as an organic solution or as an aqueous solution but the form as an aqueous solution is preferable. When an aqueous solution of a processing agent of this invention is applied, it is preferable to apply the solution at a rate of 0.1-3 weight % and more preferably 0.3-1.2 weight % as the processing agent with respect to the synthetic fiber.
[0032] Examples of synthetic fibers that may be processed by a method of this invention include (1) polyester fibers such as polyethylene terephthalate, polypropylene terephthalate and polylactic ester fibers; (2) polyamide fibers such as nylon 6 and nylon 66; (3) polyacryl fibers such as polyacrylic and modacrylic fibers; (4) polyolefin fibers such as polyethylene and polypropylene fibers and polyurethane fibers. The present invention is particularly effective, however, when applied to polyester fibers and polyamide fibers.
[0033] The invention is described next by way of test examples but it goes without saying that these examples are not intended to limit the scope of the invention. In what follows, “part” will mean “weight part” and “%” will mean “weight %” unless otherwise specified.
Part 1 (Preparation of Hydroxy Compounds)
Preparation of Hydroxy Compound (A-1)
[0034] Potassium hydroxide powder (purity 95%) 47.5 g and naphthen solvent (range of boiling point 210-230° C., specific weight 0.79) 400 g were placed inside a 1-liter autoclave and methylethyl ketone 50 g was further added after acetylene was introduced to the gauge pressure of 0.02 MPa. A reaction mixture was obtained after temperature was kept at 25° C. for 2 hours. This reaction mixture 500 g was transferred into a separation funnel and after it was washed with water to remove the potassium hydroxide, an organic phase was separated. After hydrochloric acid with concentration of 0.1 mol/L was added to this organic phase to neutralize the remaining potassium hydroxide, an organic phase 456 g containing 3,6-dimethyl-4-octine-3,6-diol was separated. This organic phase 456 g was taken inside a separation funnel, dimethyl sulfoxide 90 g was added, and it was left stationary after shaken. The lower layer 151 g formed by layer separation was collected, the naphthen solvent 363 g was added, and it was left stationary after shaken. The lower layer 140 g formed by layer separation was collected and distilled at a reduced pressure to obtain 3,6-dimethyl-4-octyne-3,6-diol as hydroxy compound (A-1).
[0000] Preparation of Hydroxy Compounds (A-2)-(A-12) and (a-1)
[0035] Hydroxy compounds (A-2)-(A-12) and (a-1) were prepared similarly as hydroxy compound (A-1) explained above.
Preparation of Hydroxy Compound (A-15)
[0036] Hydroxy compound (A-1) as described above 170 g (1 mole) and boron trifluoride diethyl ether 5 g were placed inside an autoclave and after the interior of the autoclave was replaced with nitrogen gas, a mixture of ethylene oxide 352 g (8 moles) and propylene oxide 464 g (8 moles) was pressured in under a pressured and heated condition at 60-70° C. for a reaction. A reaction product was obtained after an hour of ageing reaction. This reaction product was analyzed and found to be hydroxy compound (A-15) according to Formula 2 wherein R 7 and R 10 are each methyl group, R 8 and R 9 are each ethyl group, R 11 and R 12 are each hydrogen atom, and A 1 and A 2 are each residual group obtainable by removing hydrogen atoms from all hydroxyl groups of polyalkyleneglycol having polyoxyalkylene group formed with a total of 8 oxyethylene units and oxypropylene units.
[0000] Preparation of Hydroxy Compounds (A-16)-(A-20) and (a-2)
[0037] Hydroxy compounds (A-16)-(A-20) and (a-2) were prepared similarly as hydroxy compound (A-15) explained above.
Preparation of Hydroxy Compound (A-21)
[0038] Hydroxy compound 694 g (1 mole) obtained by adding 10 moles of ethylene oxide to 1 mole of 2,2,7,7-tetramethyl-3,6-diethyl-4-octine-3,6-diol and 48% aqueous solution of potassium hydroxide 14.5 g were placed inside an autoclave and dehydrated with stirring at 70-100° C. under a reduced pressure condition. After an etherifecation reaction was carried out by maintaining the reaction temperature at 100-120° C. and pressuring in methyl chloride 106 g (2.1 moles) until the lowering of pressure inside the autoclave became unnoticeable, a reaction product 765 g was obtained by filtering away the potassium chloride obtained as by-product. This reaction product was analyzed and found to be hydroxy compound (A-21) according to Formula 2 wherein R 7 and R 10 are each ethyl group, R 8 and R 9 are each t-butyl group, R 11 and R 12 are each methyl group, and A 1 and A 2 are each residual group obtainable by removing hydrogen atoms from all hydroxyl groups of polyalkyleneglycol having polyoxyethylene group formed with a total of 5 oxyethylene units.
[0000] Preparation of Hydroxy Compounds (A-14) and (a-3)
[0039] Hydroxy compounds (A-14) and (a-3) were prepared similarly as hydroxy compound (A-21) explained above.
Preparation of Hydroxy Compound (A-22)
[0040] Hydroxy compound 1420 g (1 mole) obtained by adding 8 moles of ethylene oxide and 14 moles of propylene oxide to 1 mole of 2,9-dimethyl-4,7-diethyl-5-decyne-4,7-diol, glacial acetic acid 144 g (2.4 moles) and concentrated sulfuric acid 12 g were placed inside a flask for an esterification reaction with stirring by maintaining the reaction temperature at 100-110° C. and dehydrating under a reduced pressure condition. After the reaction was completed, it was cooled and the concentrated sulfuric acid and the non-reacted acetic acid were neutralized with 48% potassium hydroxide 70 g and the generated water was distilled away under a reduced pressure condition. A reaction product 1420 g was obtained by filtering away organic salts obtained as by-products. This reaction product was analyzed and found to be hydroxy compound (A-22) according to Formula 2 wherein R 7 and R 10 are each ethyl group, R 8 and R 9 are each isobutyl group, R 11 and R 12 are each acetyl group, and A 1 and A 2 are each residual group obtainable by removing hydrogen atoms from all hydroxyl groups of polyalkyleneglycol having polyoxyalkylene group formed with a total of 11 oxyethylene units and oxypropylene units.
Preparation of Hydroxy Compound (A-13)
[0041] Hydroxy compound (A-13) was prepared similarly as hydroxy compound (A-21) explained above.
[0042] Details of all these hydroxy compounds obtained above are shown below, those corresponding to Formula 1 being shown in Table 1 and those corresponding to Formula 2 being shown in Table 2.
[0000]
TABLE 1
R 1
R 4
R 2
R 3
*1
R 5
R 6
A-1
Methyl
Methyl
Ethyl
Ethyl
6
Hydrogen
Hydrogen
group
group
group
group
atom
atom
A-2
Hydrogen
Hydrogen
Methyl
Methyl
2
Hydrogen
Hydrogen
atom
atom
group
group
atom
atom
A-3
Ethyl
Ethyl
Ethyl
Ethyl
8
Hydrogen
Hydrogen
group
group
group
group
atom
atom
A-4
Methyl
Methyl
n-propyl
n-propyl
8
Hydrogen
Hydrogen
group
group
group
group
atom
atom
A-5
Methyl
Methyl
Isopropyl
Isopropyl
8
Hydrogen
Hydrogen
group
group
group
group
atom
atom
A-6
Methyl
Methyl
n-butyl
n-butyl
10
Hydrogen
Hydrogen
group
group
group
group
atom
atom
A-7
Methyl
Methyl
Isobutyl
Isobutyl
10
Hydrogen
Hydrogen
group
group
group
group
atom
atom
A-8
Hydrogen
Hydrogen
n-pentyl
n-pentyl
10
Hydrogen
Hydrogen
atom
atom
group
group
atom
atom
A-9
Hydrogen
Hydrogen
n-hexyl
n-hexyl
12
Hydrogen
Hydrogen
atom
atom
group
group
atom
atom
A-10
Methyl
Methyl
t-butyl
t-butyl
12
Hydrogen
Hydrogen
group
group
group
group
atom
atom
A-11
Methyl
Methyl
Isopentyl
Isopentyl
12
Hydrogen
Hydrogen
group
group
group
group
atom
atom
A-12
Lauryl
Lauryl
Isobutyl
Isobutyl
32
Hydrogen
Hydrogen
group
group
group
group
atom
atom
A-13
Ethyl
Ethyl
Isopentyl
Isopentyl
14
Acetyl
Acetyl
group
group
group
group
group
group
A-14
Ethyl
Ethyl
Isopentyl
Isopentyl
14
Methyl
Methyl
group
group
group
group
group
group
a-1
Methyl
Methyl
Octa-
Octa-
38
Hydrogen
Hydrogen
group
group
decenyl
decenyl
atom
atom
group
group
In Table 1:
*1: Sum of carbon atom numbers of R 1 -R 4
[0000]
TABLE 2
A 1
A 2
R 7
R 10
R 8
R 9
*2
*3
*3
R 11
R 12
A-15
MG
MG
EG
EG
6
EO/4
EO/4
HA
HA
PO/4
PO/4
A-16
MG
MG
IPG
IPG
8
EO/2
EO/2
HA
HA
PO/2
PO/2
A-17
MG
MG
IBG
IBG
10
EO/7
EO/7
HA
HA
A-18
MG
MG
IPNG
IPNG
12
EO/15
EO/15
HA
HA
PO/5
PO/5
A-19
MG
MG
EG
EG
6
EO/1
EO/1
HA
HA
A-20
HA
HA
EG
EG
4
EO/25
EO/25
HA
HA
A-21
EG
EG
tBG
tBG
12
EO/5
EO/5
MG
MG
A-22
EG
EG
IBG
IBG
12
EO/4
EO/4
AG
AG
BO/7
BO/7
a-2
MG
MG
IPG
IPG
6
EO/20
EO/20
HA
HA
PO/20
PO/20
a-3
EG
EG
IPG
IPG
6
EO/5
EO/5
BG
BG
In Table 2:
*2: Sum of carbon atom numbers of R 7 -R 10
*3: Kind/Repetition number of oxyalkylene units
EO: Oxyethylene unit
PO: Oxypropylene unit
BO: Oxytetramethylene unit
HA: Hydrogen atom
MG: Methyl group
EG: Ethyl group
IPG: Isopropyl group
IPNG: Isopentyl group
IBG: Isobutyl group
tBG: t-butyl group
AG: Acetyl group
BG: Butyl group
Part 2
TEST EXAMPLE 1
Preparation of Processing Agent (P-1)
[0043] Processing agent (P-1) of Test Example 1 for synthetic fibers was prepared by uniformly mixing together 75 parts of lubricant (B-1) described below, 7 parts of hydroxy compound (A-1) shown in Table 1 as functional improvement agent, 10 parts of another functional improvement agent (C-1) described below, 1 part of still another functional improvement agent (E-1) described below and 7 parts of emulsifier (D-1) described below.
[0044] Lubricant (B-1): Mixture at weight ratio of 11/14/29/46 of dodecyl dodecanate, ester of α-butyl-ω-hydroxy (polyoxyethylene) (n=3) and dodecanoic acid, polyether monool with number average molecular weight of 3000 obtained by random addition of ethylene oxide and propylene oxide at weight ratio of 50/50 to butyl alcohol, and polyether monool with number average molecular weight of 1000 obtained by block addition of ethylene oxide and propylene oxide at weight ratio of 40/60 to butyl alcohol.
[0045] Functional improvement agent (C-1): Mixture at weight ratio 50/50 of potassium octadecenate and potassium decanesulfonate.
[0046] Functional improvement agent (E-1): Octyl diphenyl phosphite (antioxidant).
[0047] Emulsifier (D-1): Glycerol monolaurate.
TEST EXAMPLES 2-23 AND COMPARISON EXAMPLES 1-5
Preparation of Processing Agents (P-2)—(P-23) and (R-1)-(R-5)
[0048] Processing agents (P-2)-(P-23) and (R-1)-(R-5) of Test Examples 2-23 and Comparison Examples 1-5 for synthetic fibers were prepared similarly as processing agent (P-1) described above.
[0049] Details of these processing agents are summarized in Table 3.
[0000]
TABLE 3
Functional
improvement agents
Hydroxy
Lubricant
compound
Others
Emulsifier
Kind
Kind
Ratio
Kind
Ratio
Kind
Ratio
Kind
Ratio
Test
Exam-
ples
1
P-1
B-1
75
A-1
7
C-1
10
D-1
7
E-1
1
2
P-2
B-1
65
A-2
12
C-2
9
D-2
14
3
P-3
B-1
55
A-3
18
C-1
9
D-3
18
4
P-4
B-2
65
A-4
7
C-1
13
D-2
14
E-2
1
5
P-5
B-2
55
A-5
12
C-2
15
D-3
18
6
P-6
B-3
75
A-6
7
C-1
11
D-1
7
7
P-7
B-3
65
A-7
7
C-2
11
D-3
16
E-3
1
8
P-8
B-4
65
A-8
12
C-3
7
D-3
16
9
P-9
B-1
65
A-9
18
C-1
3
D-2
14
10
P-10
B-2
65
A-10
7
C-2
11
D-3
16
E-3
1
11
P-11
B-1
65
A-11
12
C-4
9
D-2
14
12
P-12
B-2
80
A-12
3
C-5
5
D-2
12
13
P-13
B-1
54
A-13
26
C-6
5
D-3
15
14
P-14
B-1
65
A-14
7
C-1
12
D-3
16
15
P-15
B-1
75
A-15
7
C-1
11
D-1
7
16
P-16
B-2
65
A-16
12
C-2
8
D-2
14
E-1
1
17
P-17
B-2
55
A-17
18
C-1
9
D-3
18
18
P-18
B-3
65
A-18
12
C-1
9
D-2
14
19
P-19
B-4
65
A-18
12
C-2
8
D-2
14
E-3
1
20
P-20
B-1
65
A-19
12
C-1
9
D-2
14
21
P-21
B-2
80
A-20
2
C-5
6
D-1
12
22
P-22
B-5
54
A-21
28
C-6
3
D-3
15
23
P-23
B-2
65
A-22
10
C-5
11
D-2
14
Com-
parison
Exam-
ples
1
R-1
B-2
65
a-1
18
C-3
3
D-2
14
2
R-2
B-2
65
a-2
18
C-3
3
D-2
14
3
R-3
B-2
65
a-3
18
C-3
3
D-2
14
4
R-4
B-2
70
A-14
0.5
C-3
14.5
D-2
15
5
R-5
B-2
54
A-14
33
C-3
7
D-2
6
In Table 3:
Ratio: Weight part;
B-1: Mixture of dodecyl dodecanate, ester of α-butyl-ω-hydroxy (polyoxyethylene) (n = 3) and dodecanoic acid, polyether monool with number average molecular weight of 3000 obtained by random addition of ethylene oxide and propylene oxide at weight ratio of 50/50 to butyl alcohol, and polyether monool with number average molecular weight of 1000 obtained by block addition of ethylene oxide and propylene oxide at weight ratio of 40/60 to butyl alcohol at weight ratio of 11/14/29/46;
B-2: Mixture of lauryl octanate, polyether monool with number average molecular weight of 3000 obtained by random addition of ethylene oxide and propylene oxide at weight ratio of 65/35 to butyl alcohol, and polyether monool with number average molecular weight of 2500 obtained by random addition of ethylene oxide and propylene oxide at weight ratio of 40/60 to butyl alcohol at weight ratio of 30/20/50;
B-3: Mixture of polyether monool with number average molecular weight of 10000 obtained by random addition of ethylene oxide and propylene oxide at weight ratio of 50/50 to butyl alcohol, polyether monool with number average molecular weight of 2500 obtained by random addition of ethylene oxide and propylene oxide at weight ratio of 50/50 to lauryl alcohol, and polyether monool with number average molecular weight of 1000 obtained by block addition of ethylene oxide a nd propylene oxide at weight ratio of 45/55 to octyl alcohol at weight ratio of 30/50/20;
B-4: Mixture of lauryl octanate and mineral oil with viscosity 1.3 × 10 −5 m 2 /s at 30° C. at weight ratio of 67/33;
B-5: Mixture of mineral oil with viscosity 3.0 × 10 −5 m 2 /s at 30° C., lauryl acid ester of α-butyl-ω-hydroxy (polyoxyethylene) (n = 8), and polyether monool with number average molecular weight of 1800 obtained by block addition of ethylene oxide and propylene oxide to butyl alcohol at weight ratio of 24/16/60;
A-1-A-22, a-1-a-3: Hydroxy compounds prepared in Part 1 and described in Tables 1 and 2.
D-1: Glycerol monolaurate;
D-2: α-dodecyl-ω-hydroxy (polyoxyethylene) (n = 7);
D-3: Mixture of castor oil with addition of 20 moles of ethylene oxide and diester of 1 mole of polyethylene glycol with average molecular weight of 600 and 2 moles of lauric acid at weight ratio of 80/20;
C-1: Mixture of potassium octadecenate and potassium decane sulfonate at weight ratio of 50/50;
C-2: Mixture of butyl diethanol amine laurate, sodium octadecyl benzene sulfonate, and potassium phosphoric acid ester of α-lauryl-ω-hydroxy (trioxyethylene) at weight ratio of 50/25/25;
C-3: Mixture of tributyl methyl ammonium diethylphosphate and sodium octadecyl benzene sulfonate at weight ratio of 60/40;
C-4: Mixture of dimethyl lauryl amine oxide and tributylmethyl ammonium diethyl phosphate at weight ratio of 50/50;
C-5: Mixture of tributylmethyl ammonium diethyl phosphate and lauryl trimethyl ammonium ethylsulfate at weight ratio of 60/40;
C-6: Mixture of decyl dimethyl ammonio acetate and N,N-bis(2-carboxyethyl)-octylamine at weight ratio of 50/50;
E-1: Octyl diphenyl phosphite (antioxidant);
E-2: 3,5-di-t-butyl-4-hydroxy-toluene (antioxidant);
E-3: dilauryl-3,3′-thiopropionate (antioxidant).
Part 3 (Attachment of Processing Agents to Synthetic Fibers, False Twisting and Evaluation)
[0050] Each of the processing agents prepared in Part 2 was diluted with water to prepare a 10% aqueous solution. After polyethylene terephthalate chips with intrinsic viscosity of 0.64 and containing titanium oxide by 0.2% were dried by a known method, they were spun at 295° C. by using an extruder. The 10% aqueous solution thus prepared was applied onto the yarns extruded out of the nozzle to be cooled and solidified by a guide oiling method using a measuring pump such that the attached amount of the processing agent became as shown in Table 4. Thereafter, the yarns were collected by means of a guide and wound up at the rate of 3000 m/minute without any drawing by a mechanical means to obtain partially oriented 56 decitex-144 filament yarns as wound cakes of 10 kg.
False Twisting
[0051] The cakes thus obtained as described above were subjected to a false twisting process under the conditions described below by using a false twister of the contact heater type (product name of SDS1200 produced by Teijinseiki Co., Ltd.):
[0000] Fabrication speeds: 800 m/minute and 1200 m/minute; Draw ratio: 1.652; Twisting system: Three-axis disk friction method (with one guide disk on the inlet side, one guide disk on the outlet side and four hard polyurethane disks); Heater on twisting side: Length of 2.5 m with surface temperature of 210° C.; Heater on untwisting side; None; Target number of twisting; 3300T/m.
The false twisting process was carried out under the conditions given above by a continuous operation of 25 days.
Evaluation of Fluffs
[0052] In the aforementioned false twisting process, the number of fluffs per hour was measured by means of a fly counter (produce name of DT-105 produced by Toray Engineering Co., Ltd.) before the false twisted yarns were wound up and evaluated according to the standards as described below:
[0053] A: The measured number of fluffs was zero;
[0054] A-B: The measured number of fluffs was less than 1 (exclusive of zero);
[0055] B: The measured number of fluffs was 1-2;
[0056] C: The measured number of fluffs was 3-9;
[0057] D: The measured number of fluffs was 10 or greater.
[0000] The results of the measurement are shown in Table 4.
Evaluation of Yarn Breaking
[0058] The number of occurrences of yarn breaking during the 25 days of operation in the false twisting process described above was converted into the number per day and such converted numbers were evaluated according to the standards as described below:
[0059] A: The number of occurrence was zero;
[0060] A-B: The number of occurrence was less than 0.5 (exclusive of zero);
[0061] B: The number of occurrence was 0.5 or greater and less than 1;
[0062] C: The number of occurrence was 1 or greater and less than 5;
[0063] D: The number of occurrence was 5 or greater.
[0000] The results are shown in Table 4.
Dyeing Property
[0064] A fabric with diameter of 70 mm and length of 1.2 m was produced from the false-twisted yarns on which fluffs were measured as above by using a knitting machine for tubular fabric. The fabric thus produced was dyed by a high temperature and high pressure dyeing machine by using disperse dyes (product name of Kayalon Polyester Blue-EBL-E produced by Nippon Kayaku Co. Ltd.). The dyed fabrics were washed with water, subjected to a reduction clearing process and dried according to a known routine and were thereafter set on an iron cylinder with diameter 70 mm and length 1 m. An inspection process for visually counting the number of points of densely dyed potion on the fabric surface was repeated five times and the evaluation results thus obtained were converted into the number of points per sheet of fabric. The evaluation was carried out according to the following standards:
[0065] A: There was no densely dyed portion;
[0066] A-B: There was 1 point of densely dyed portion;
[0067] B: There were 2 points of densely dyed portion;
[0068] C: There were 3-6 points of densely dyed portion;
[0069] D: There were 7 or more points of densely dyed portion.
[0000] The results are shown in Table 4.
[0070] This invention, as described above, has the favorable effects of sufficiently preventing the occurrence of fluffs, yarn breaking and dyeing specks even when synthetic fibers of new kinds such as low denier synthetic fibers, high multifilament synthetic fibers and modified cross-section synthetic fibers are being produced at a fast rate.
[0000]
TABLE 4
Processing agent
Rate of
800 m/minute
1200 m/minute
attachment
Yarn
Dyeing
Yarn
Dyeing
Kind
(%)
Fluffs
breaking
property
Fluffs
breaking
property
Test
Example
24
P-1
0.4
A
A
A
A
A
A
25
P-1
0.8
A
A
A
A
A
A
26
P-2
0.6
A
A
A
A
A
A
27
P-2
0.3
A
A
A
A
A
A
28
P-3
0.6
A
A
A
A
A
A
29
P-3
0.8
A
A
A
A
A
A
30
P-4
0.4
A
A
A
A
A
A
31
P-5
0.5
A
A
A
A
A
A
32
P-6
0.4
A
A
A
A
A
A
33
P-7
0.4
A
A
A
A
A
A
34
P-8
0.4
A
A
A
A
A
A
35
P-9
0.4
A
A
A
A-B
A
A
36
P-10
0.4
A
A
A
A
A-B
A
37
P-11
0.4
A
A-B
A
A
A-B
A
38
P-12
0.4
A-B
A
A
A-B
A-B
A-B
39
P-13
0.4
A
A-B
A
A-B
A-B
A-B
40
P-14
0.5
A-B
A
A
A-B
A-B
A-B
41
P-15
0.4
A-B
A-B
A
A
A
A
42
P-16
0.4
A
A
A
A-B
A
A
43
P-17
0.4
A
A
A
A-B
A
A
44
P-18
0.5
A
A
A
A-B
A
A
45
P-19
0.6
A
A
A
A
A
A-B
46
P-20
0.4
A-B
A-B
B
B
A-B
B
47
P-21
0.4
A-B
B
A-B
A-B
B
B
48
P-22
0.4
A-B
B
A-B
B
B
A-B
49
P-23
0.4
A-B
B
A-B
B
B
A-B
Comparison
Example
6
R-1
0.4
D
D
D
C
D
C
7
R-2
0.4
C
C
C
D
D
D
8
R-3
0.4
C
D
C
D
D
C
9
R-4
0.4
C
C
D
D
D
D
10
R-5
0.4
C
C
D
D
D
D | A processing agent for synthetic fibers contains a lubricant, a functional improvement agent and an emulsifier, each containing a specified kinds of components by a specified amount and also by a specified total amount so as to have improved characteristics of preventing occurrence of fluffs, yard breaking and uneven dyeing when applied to synthetic fibers at a specified rate. | 3 |
BACKGROUND OF THE INVENTION
1. Technical Field of the Invention
This invention relates to an ignition timing control device for internal combustion engines which controls the ignition timing in response to a knocking state of the engine.
2. Description of the Prior Art
The setting of the ignition timing for an internal combustion engine is carried out for optimum efficiency with regard to the operating state of the engine. In general, it is desirable to set the ignition timing to approach MBT (Minimum advance for Best Torque) as nearly as possible within a range in which knocking, or delayed detonation of unburned pockets of fuel, within the engine does not occur. However, the conventionally employed ignition timing control devices have mostly been mechanical, with ignition advance characteristics that are inconsistent, due to production tolerances and variations due to age. For this reason, it has been necessary to avoid knocking in practice by setting the ignition timing somewhat retarded of the ignition advance characteristics. This has adversely affected the efficiency of the engine. Furthermore, even if an ignition timing control device without production tolerances and variations with age could be provided, the knocking phenomenon itself is influenced by factors such as the temperature and humidity of the engine's intake air, as well as the air-fuel mix ratio, etc., such that setting the ignition timing to avoid knocking under a certain set of conditions cannot eliminate the possibility of knocking under a different set of operating conditions.
In this situation, it is possible to apply a system of detecting the onset of knocking to control the ignition timing in such a way that knocking virtually never occurs, even when errors in the ignition advance characteristics arise due to the aforementioned mechanical tolerances or differences in the operating conditions. Essentially, this means appropriately retarding the ignition timing at the onset of knocking, so as to eliminate knocking.
There are various methods for detecting the onset of knocking, including measuring the pressure inside the combustion chamber, measuring the vibrational acceleration of the engine, and measuring the sound produced by the engine, etc., but in terms of practical application, from considerations such as the siting of the detector and signal processing, etc., the method whereby the vibrational acceleration of the engine is measured is regarded as the most practical. However, with this method, mechanical vibration noises that are unconnected with the knocking produced by the engine are picked up simultaneously with the knocking signal, and so it is necessary to discriminate the knocking signal from among the mechanical vibration noises.
SUMMARY OF THE INVENTION
It is an object of this invention to make possible ignition timing control for good engine efficiency by retarding the ignition timing in response to a knocking stae of the engine, so as to suppress the production of such knocking.
This and other objects of the present invention are achieved by providing in a discrimination circuit for the discrimination of a knocking signal component in the output of a vibration sensor, a level detecting means which accepts the vibration sensor output and generates a comparative signal level responsive to the noise signal level thereof, a comparator which distinguishes by level a knocking signal by comparing the comparative signal level and the vibration sensor output, and a feedback means which prevents the passage of the vibration sensor output with regard to the level detection means when the comparator generates an output and which inverts the magnitude relationship of the various inputs to the comparator when the compartor's output continues for at least a predetermined duration so as to cause the production of the output of the comparator to cease, whereby the level of the knocking signal is accurately distinguished to enable suitable control of the ignition timing to be effected with regard to knocking, and whereby even if a noise signal is erroneously detected as knocking, after the passage of a predetermined period of time, the erroneous detection is automatically invalidated so as to restore ignition timing control in accordance with true knocking.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a circuit/block diagram showing an embodiment according to the present invention;
FIG. 2 is a frequency vs. amplitude curve of the acceleration sensor of FIG. 1; and
FIGS. 3 and 4 are operational waveforms of various parts in FIG. 1.
DESCRIPTION OF THE PREFERRED EMBODIMENT
FIG. 1 is a hybrid electrical circuit/block diagram showing a preferred embodiment of the present invention, wherein an acceleration sensor (1) which detects the vibrational acceleration of an engine is fitted to an engine (not shown); the output from the acceleration sensor (1) passes through a bandpass filter (2) having high sensitivity with regard to the knocking in the output signal, and which allows a certain frequency component to pass; a noise level detector (3) comprises an amplifier (31) which amplifies the output from the bandpass filter (2) to a slightly higher voltage, resistances (32) and (33), a diode (34), and a resistance (35) and a capacitor (36) which constitute an integrator; the detector detects the level of the mechanical vibration noise which is not connected with the knocking in the engine. A comparator (4) compares the output voltage from the aforementioned bandpass filter (2) with the output voltage from the aforementioned noise level detector (3), and produces a knocking detection pulse; and a feedback circuit (5), comprising a resistance (51) and a diode (52), constitutes the charging circuit for the aforementioned capacitor (36), and which lowers the inverted input terminal voltage of the aforementioned amplifier (31) so as to prevent the passage of the output from the aforementioned bandpass filter (2) during a time when the aforementioned knocking detection pulse is produced. An integrator (6) integrates the output pulse of the comparator (5) and produces an integration voltage corresponding to the strength of the knocking in the engine; a phase shifter (7) retards the phase of a standard ignition signal in accordance with the output voltage of the integrator (6), and a standard ignition timing signal generator (8) that generates a standard ignition signal in accordance with pre-established ignition timing characteristics (which are established at least within the knocking range in which engine knocking occurs) and is normally housed within the distributor, is operated to obtain the abovementioned ignition timing characteristics. A waveshaping circuit (9) shapes the output waveform of the standard ignition timing signal generator (8), and at the same time controls the closing angle for passing the current from the ignition coil, a drive circuit (10) switches a Darlington output transistor (12) in series with a power supply circuit of the ignition coil (11), in accordance with the output signal from the phase shifter (7).
In FIG. 2 is shown a curve of the frequency characteristics of the output signal from the acceleration sensor (1). The broken line (A) represents the output without any knocking, and the solid line (B) represents the output when knocking is present. The output signal of the acceleration sensor (1) includes both the knocking signal and mechanical noise signal which is not connected unconnected with the knocking in the engine, as well as various noise components that find their way into the signal transmission path.
Comparing the characteristics of (A) and (B) in FIG. 2, it will be seen that there is a distinctive frequency characteristic to the knocking signal. Differences in the characteristic distribution occur in accordance with differences in the engines, or differences in the siting of the acceleration sensor, but a clear difference always exists between the absence and existence of knocking. Therefore, by allowing a frequency component to pass which includes this knocking signal, it is possible to effectively suppress noises of other frequency components, thereby enabling the knocking signal to be detected effectively detected.
FIGS. 3 and 4 show the operational waveforms of various portions of FIG. 1; FIG. 3 shows the mode in which there is an absence of engine knocking, and FIG. 4 shows the mode in which knocking exists.
Next the operation of this embodiment is explained.
A standard ignition timing signal generated by the standard ignition timing signal generator (8) in accordance with ignition timing characteristics predetermined to be in accordance with the rotation of the engine, is wave-shaped into a pulse with a desired closing angle, by the waveshaping circuit (9), to drive the output transistor (12) via the phase shifter (7) and the drive circuit (10), intermittently interrupting the current passing through the ignition coil (11), whereby the engine is driven by suitably timed ignition of an air-fuel mixture fed into the combustion chamber or chambers of the engine, by an ignition voltage from the ignition coil (11), produced when the aforementioned current flow is interrupted. During operation of the engine, certain vibrations are produced, and these are detected by means of the acceleration sensor (1).
At this point, if no knocking is produced in the engine, no knocking induced mechanical vibrations will be produced, but mechanical vibrational noises due to other mechanical vibrations will be produced in the output signal of the acceleration sensor (1), as shown in FIG. 3(a). This noise signal is passed through the bandpass filter (2) wherein as shown by FIG. 3(b), the level of the output noise component is lowered because the mechanical noise component, apart from a specific band, is suppressed. The vibration output from the bandpass filter (2) is voltage amplified to a slightly higher voltage level by the amplifier (31) of the level detector (3), the degree of this voltage amplification being determined by the resistance values of the resistances (32) and (33). This voltage amplified vibration output from the amplifier (31) charges the capacitor (36) via the resistance (35), and discharges it via the resistances (35), (32) and (33), whereby it is transformed into a direct current voltage. The charge and discharge time constant in this instance is set a value such that mild changes in the peak voltage level in the output signal from the amplifier (31), such as those which occur with mechanical vibration noises that are not a knocking signal, are responded to, and so the level output is a direct current voltage which slightly higher than the mechanical vibration noise peak value (Refer to FIG. 3(b)-(ii)). Accordingly, the output voltage of the noise level detector (3) is greater than the output signal voltage from the bandpass filter (2), and so the output of the comparator (4) that compares them produces absolutely no output, as shown in FIG. 3(c), and consequently the noise signal is removed entirely. Thus, the output voltage of the integrator (6) is zero, as shown in FIG. 3(d), and so the phase shift produced by the phase shifter (7) (the phase difference between input and output (FIGS. 3(e) and (f))), is also zero. Consequently, the intermittent phase of the current passing through the ignition coil (11) is the same as the phase of the output of the waveshaping circuit (9), and the engine's ignition timing in the standard ignition timing based on the standard ignition timing signal from the standard ignition timing signal generator (8), and the ignition timing is not retarded.
Next, the situation where knocking occurs is as shown in FIG. 4, with a knocking signal at a time delayed by a certain amount after the ignition timing point (FIGS. 4(a) to (f)), as shown in FIG. 4(a), being included in the acceleration sensor's output. This signal is passed through the bandpass filter (2), after which, as shown in FIG. 4(b) (i), the knocking signal is overlaid with considerable magnitude on top of the mechanical vibration noise unrelated to the knocking. Also, in the output signal from the aforementioned bandpass filter (2), the rise and fall of the knocking signal is extremely fast, and so the charge and discharge response of the capacitor (36) in the noise level detector (3) falls behind, and so the output voltage level becomes substantially constant, not rising in response to the knocking signal level, as shown in FIG. 4(b) (ii).
The result of this is that voltages shown by FIGS. 4(b) (i) and 4(b) (ii) are input to the inputs to the comparator (4), and so a pulse is produced that appears in the output of the comparator (4) in response to the knocking signal, as shown in FIG. 4(c). Subsequently, the integrator (6) integrates this pulse, producing an integration voltage as shown in FIG. 4(d). Then, in response to the voltage output of the integrator (6) the phase shifter (7) retards the output signal (FIG. 4(e)) from the waveshaping circuit (9), whereby the output voltage pulse from the phase shifter (7) is retarded in relation to the phase of the output voltage pulse from the waveshaping circuit (9), as shown in FIG. 4(f), and the drive circuit (10) drives the output transistors (12) at this phase, so the retardation angle of the ignition timing is controlled in accordance with the strength of the knocking phenomenon, to retard the ignition behind the predetermined standard ignition timing, thus suppressing the generation of knocking, and controlling the ignition timing so that it is ultimately substantially ideal.
At this point, when the comparator (4) produces a knocking detection signal, the knocking detection signal raises the inverted input terminal voltage of the amplifier (31) to the input voltage of the noninverted input terminals, or higher, via the resistance (51) and the diode (52) of the feedback circuit (5). For this reason, the charging, by the output of the amplifier (31), of the capacitor (36), which had been integrating level the output of the amplifier (31) ceases, and so the output of the noise level detector (3), i.e. the comparative voltage level from the comparator (4), does not increase during a period in which the knocking signal is produced, and even in the vicinity of the time points (t 1 , t 2 ) at which the knocking signal terminates, the level is substantially the same as that immediately prior to the occurrence of knocking, and so the comparator (4) is able to accurately determine the knocking signal level to appropriately control the ignition timing.
However, in a case when, as described above, a voltage rise in the capacitor (36) is prevented by the output of the comparator (4), if a noise signal of a level lower than the knocking signal is erroneously detected by the comparator (4) as a knocking signal, even momentarily, when, for whatever reason, the output voltage level of the noise level detector (3) becomes lower than the noise level in the output from the bandpass filter (2), the erroneous detection signal prevents the production of an output from the amplifier (31), and so the output voltage level of the noise level comparator (3) is kept low. Thus, although there is the possibility that the comparator's erroneous detection output may continue for a relatively long period of time, with the device of the present invention, the charging of the capacitor (36) by the output of the bandpass filter (2) via the resistance (51) and the diode (52) of the feedback circuit is prevented by the detection output of the comparator (4), while the capacitor is charged with a large time coefficient determined by the resistances (32), (35) and (51), and after a predetermined time the output level of the level detector (3) is always raised to the noise level of the output from the bandpass filter (2) of the input of the comparator (4), or higher, and the generation by the comparator (4) of an erroneous detection signal over a long period of time is prevented, allowing restoration to correct operation. In these circumstances, if the resistance values of the resistances (35), (32) and (51) are selected such that the time constant for charging the capacitor (36) by means of the output of the comparator (4) is sufficiently larger (several tens to several hundred times) than the time constant by means of the output of the amplifier (31), it will be possible to suitably discriminate the level of the knocking signal, without in practice raising the comparative level of the comparator (4) during the period in which knocking is produced in the output of the bandpass filter (2), and even if the comparative level were for some reason to fall below the noise signal level, such that a noise signal might be erroneously detected, after the passage of a predetermined period of time, correct operation is automatically restored.
Thus, in an embodiment as hereinabove described, when the comparator (4) produces a detection output, the charging of the comparative level generating capacitor (36) by the output of the bandpass filter (2) is prevented, while the capacitor (36) is charged by the output of the abovementioned detector via a circuit with a sufficiently large time constant, and, after a predetermined period of time the various inputs of the comparator (4) are inverted in terms of their magnitude relationship.
This invention comprises a means of controlling the ignition timing of an internal combustion engine in response to a state of knocking in that engine, comprising charging a capacitor by means of the detection output of a comparator via a circuit with a sufficiently large time constant, and, after a predetermined period of time, inverting the magnitude relationship of the inputs of the comparator, but may equally be applied to ignition timing controls for internal combustion engines, provided with a timer circuit to measure the sustain time of the comparator's detection output, the capacitor being rapidly charged after the passage of the sustain time, causing the magnitude relationship of the various inputs to the comparator to be inverted so as to invalidate erroneous detections. | This invention enables substantially ideal ignition timing to be achieved by suitably detecting a knocking signal while avoiding interference from the various noise components in the output of a vibrational acceleration sensor on an engine, and controlling the ignition timing in response to the knocking signal, and even if, for whatever reason, a noise signal is erroneously detected as a knocking signal, the erroneous detection is invalidated so as to allow suitable ignition timing control in response to the real knocking signal. | 5 |
FIELD OF THE ART
[0001] The present invention relates to the construction of apartment buildings, proposing an automated system for construction which speeds up the construction process, with an important reduction of the time and labor necessary, based on structural and building concepts different from conventional concepts.
STATE OF THE ART
[0002] In the construction of apartment buildings today, a system of reinforced concrete columns and beams is used, on which the platforms of the floors of different heights, also made of concrete, are carried out to then build with bricks, blocks or other elements, the exterior enclosing walls and the interior dividing partitions to define the openings or spaces of the apartments. In addition, the surfaces of the walls, partitions and ceilings must subsequently be coated with finishing plaster.
[0003] Said system for construction is essentially implemented manually, so it requires a great deal of labor, resulting in abundant occupational hazards, as the manufacturing times and costs are very high.
OBJECT OF THE INVENTION
[0004] According to the invention, a system for construction is proposed which is carried out with automatic process means, based on a structural building with concepts different from those of conventional buildings, such that it can be carried out in an automated manner with more precise and higher quality results.
[0005] This system object of the invention is developed by means of a large-sized supporting structure which is movably mounted on displacement rails, said structure covering a space which goes beyond the dimensions of the building to be constructed, including platforms moving in vertical displacement mode, on which platforms the molding pieces for making double walls and floor platforms are lifted, whereas a gantry crane is incorporated in the upper part of the structure, which gantry crane can in turn be mounted to move in vertical displacement mode, and stores on the sides which can also move in vertical displacement mode.
[0006] The supporting structure consists of vertical poles in the lower part of which there are arranged pumps connected with pipes extending through the mentioned poles to impel the construction concrete to the necessary height.
[0007] Containers for concrete manufacturing materials are arranged in addition to the supporting structure, whereas the different elements to be used in construction are housed in the mobile stores, including thereamong particular formwork panels for building partitions.
[0008] Said formwork panels are structured in the form of large metal boxes with insulating material filler, including therein pneumatic screw spindles for the lashings in the application assembly, as well as a heat accumulation block for maintaining a suitable temperature (about 37° C.) for the concrete pouring for construction, and a vibrating mechanism to facilitate stripping.
[0009] These formwork panels are furthermore provided with mobile parts that can be extracted towards the front to act as male parts for building door or window openings in the concrete pouring for the construction of the application partitions.
[0010] The construction of a building on a previously prepared foundation is possible with such means, arranging the supporting structure on the construction site, such that the double walls for enclosing the contour of the building and the floor platforms for the different interior enclosures of the construction are constructed on site at the molding tables, said walls and platforms being carried by means of the gantry crane to their placement positions, the gantry crane itself then placing the formwork panels for the partitions on the floor platforms in the distribution corresponding with the partitioning of enclosures to be built, arranging the installations of electricity, plumbing installations, etc., between such formwork panels and then filling the openings with concrete.
[0011] A single construction of the entire distribution of spaces in each floor of the building is thus achieved, all made entirely of concrete, without bricks, arches, joists and other different elements that are used in conventional construction.
[0012] The operating process of this system of the invention can be carried out automatically with computer-controlled functional means, which considerably reduces the necessary labor and the risks of accidents, a much quicker and higher quality construction being achieved than with conventional manual operation.
[0013] The construction is done floor by floor, the functional means being displaced by the supporting structure to the height of the floor to be constructed in each case, such that during the construction of the exterior enclosure and partitions in a floor, other operations, such as the placement of doors and windows, covering of floors, and even furnishings, can be carried out in other lower floors, with the possibility that the lower floors are finished entirely during the construction of the upper floors, which in turn entails a huge reduction of the overall time for entire building.
[0014] Furthermore, considerable savings in terms of materials is obtained because the disposable wastes are considerably reduced, which also results in a savings in transport costs and the accumulation in dumps, with the subsequent environmental impact and contamination.
[0015] Therefore, the system of the invention has clearly advantageous features, acquiring its own identity and preferred character with respect to the conventional method for the construction of buildings.
DESCRIPTION OF THE DRAWINGS
[0016] FIG. 1 shows a schematic perspective view of the supporting structure for the development of the system of the invention.
[0017] FIG. 2 is a schematic plan view of the structural operating assembly of said system of the invention, with the depiction of an apartment constructed inside it.
[0018] FIG. 3 is a plan view of the construction of the partitioning of an apartment according to the invention.
[0019] FIG. 4 is a perspective view of the structural form of an apartment constructed according to the invention.
[0020] FIG. 5 is a section view of the construction of a double wall for the exterior enclosures according to the system of the invention.
[0021] FIG. 6 is a section view of a platform for building a floor according to said system of the invention.
[0022] FIG. 7 is a detail view of the connection between the partitions and the floor platforms in the construction of an apartment according to the invention.
[0023] FIG. 8 is a front view, without the front wall, of a formwork panel of the partitions.
[0024] FIGS. 9 and 10 are respective views of the upper part and of the lower part of the front formwork panel.
[0025] FIG. 11 is a view of the front face on which the formwork panel receives the concrete.
[0026] FIG. 12 is a profile view of two facing formwork panels, with their male parts connected to build a door opening.
[0027] FIG. 13 shows a vertical section of a construction example carried out according to the system of the invention.
[0028] FIG. 14 is a schematic perspective view of an embodiment of the supporting structure with side protections in the upper contour.
DETAILED DESCRIPTION OF THE INVENTION
[0029] The object of the invention relates to a system for construction which allows an automated and programmed process, supplying the necessary materials when they are to be applied, a construction with anti-earthquake and fireproof properties, and with suitable heat and acoustic insulation being achieved.
[0030] The system is developed according to a construction process which is carried out on a traditionally prepared foundation in the application site, arranging a large-sized supporting structure ( 1 ) resting on displacement rails ( 2 ) installed longitudinally on the sides of the space occupied by the building to be constructed.
[0031] Said supporting structure ( 1 ) has plan and height dimensions exceeding those of the building to be constructed, incorporating stores ( 3 ) moving in vertical displacement mode, in which elements necessary for the construction are housed, which elements are supplied from containers ( 3 . 1 ) located on the ground.
[0032] This supporting structure ( 1 ) furthermore includes platforms ( 4 , 5 ) also moving in vertical displacement mode, there being arranged on the floor or in the lower platform ( 4 ) a table ( 6 ) for the molded building of double walls ( 7 ) as depicted in FIG. 5 , and a table ( 8 ) for the molded building of floor platforms ( 9 ) as depicted in FIG. 6 .
[0033] At the upper part of the mentioned supporting structure ( 1 ) there is arranged a gantry crane ( 10 ) which can be installed at a fixed height on the end of the supporting structure ( 1 ), or also moving in vertical displacement mode, for example by means of being supported on the mobile platform ( 5 ).
[0034] The supporting structure ( 1 ) is made up of several vertical poles with respect to which there are arranged in the lower part pumps ( 11 ) which allow impelling concrete through ducts ( 12 ) included in the mentioned poles of the supporting structure ( 1 ), for supplying said concrete for the application concrete pouring in the floors of the building to be constructed. In addition to the supporting structure ( 1 ), there are arranged aggregate stores ( 13 ) from which the materials for forming the concrete intended for the concrete pouring to be carried out are supplied.
[0035] All the elements necessary for carrying out the construction of a building according to the proposed system are housed in the stores ( 3 ) and platform ( 4 ) incorporated in the supporting structure ( 1 ) in a classified manner, formwork panels ( 14 ) intended for building the partitions of the apartments in the floors of the buildings to be constructed being provided.
[0036] Each formwork panel ( 14 ) consists ( FIG. 8 ) of a box-shaped metal structure with insulating material filler, a series of pneumatic screw spindles ( 15 ), intended for lashing the panel in application mounting being located therein, which screw spindles ( 15 ) are actuated by means of a compressor ( 16 ) which is also housed inside the respective panel ( 14 ).
[0037] A heat accumulation block ( 17 ) provided with a resistor ( 18 ), by means of which a temperature of the panel is maintained around 37° C., thus favoring the setting conditions of the concrete in the application formworks, is furthermore housed inside each panel ( 14 ).
[0038] A vibrating mechanism ( 19 ) is also included inside each panel ( 14 ), by means of which mechanism the release of the panel with respect to the concrete in the stripping is facilitated.
[0039] The electric powered functional elements installed in the equipment of each panel ( 14 ) are supplied from a battery ( 20 ) which is also housed inside the corresponding panel, connectors ( 21 ) being provided for the connection to photovoltaic electrodes or the grid for the purpose of recharging the battery ( 20 ) during the storage of the panel.
[0040] As can be observed in FIG. 10 , the lower face of the panel ( 14 ) has holes ( 22 ) for the exit of the rods of the corresponding pneumatic screw spindles ( 15 ), and holes ( 23 ) intended for being fitted on positioning guides in the application assembly of the panel.
[0041] As can be observed in FIGS. 8 and 9 , the upper face of the panel ( 14 ) has a central lashing ( 24 ) for the hoisting and movements thereof in its placement and removal with respect to the application mounting by means of the gantry crane ( 10 ) of the system, and lashings ( 25 ) displaced towards the ends for precise handling movements.
[0042] The panels ( 14 ) are complemented at the ends with padding ( 26 ) made of a synthetic material, such as polyurethane, through which the rods of the pneumatic screw spindles ( 15 ) of the ends of the panel ( 14 ) pass for the connection with other panels or on a wall in the application mounting, such that said padding ( 26 ) acts as a joint in the attachments determined by a good finish of the concrete in the formworks.
[0043] The construction of a building with the described means using the system of the invention is carried out according to the following operating process:
[0044] First the necessary foundation is built in the construction site in a conventional manner, installing on the foundation the supporting structure ( 1 ) such that the space of the construction is comprised therein, the construction of the building being done floor by floor with the means incorporated in said supporting structure ( 1 ), such that the construction of each floor serves as a support for the next floor, the means of the supporting structure ( 1 ) moving up to the operating height for the construction of each floor, such that the movement of the pieces of the construction is carried out with minimal lifting displacement.
[0045] For the construction of each floor of the building, the double walls ( 7 ) necessary for the exterior enclosure of the floor are made in the molding table ( 6 ), carrying said walls ( 7 ) by means of the gantry crane ( 10 ) to their placement position site, forming with them the enclosure of the contour of the floor in construction.
[0046] As can be observed in FIG. 5 , the building of the mentioned double walls ( 7 ) is done in molds ( 27 ), in which there are arranged metal framework ( 28 ) intended for providing structural strength to the mentioned walls ( 7 ), and lances ( 29 ) for the connection of these walls ( 7 ) with the space dividing partitions in the floor, as well as the pipes ( 30 ) necessary for the installations that must be included in the walls ( 7 ), a layer of concrete ( 7 . 1 ) being incorporated with respect to the assembly thus arranged at the bottom of the mold ( 27 ) and another layer of concrete ( 7 . 2 ) in the upper part, on an insulating material plate ( 31 ).
[0047] Exterior covering plates ( 32 ) can be arranged on the upper layer of concrete ( 7 . 2 ) by means of hardware ( 33 ) embedded in said layer of concrete ( 7 . 2 ), whereby the walls ( 7 ) are completely finished with a ventilated façade covering.
[0048] On the other hand, floor platforms ( 9 ) corresponding with the dividing spaces provided in the floor are built on the molding table ( 8 ), said platforms ( 9 ) being carried in turn with the gantry crane ( 10 ) to the placement sites corresponding with the dividing spaces for which they are intended, where they are supported on the partitions and/or walls of the floor constructed at the previous height level.
[0049] As depicted in FIG. 6 , said floor platforms ( 9 ) include lugs ( 34 ) for the fitting of the formwork panels ( 14 ) by means of their lower holes ( 23 ), and threaded bushings ( 35 ) for securing said formwork panels ( 14 ) by means of their lower pneumatic screw spindles ( 15 ).
[0050] Once the exterior enclosure of the contour has been built by means of the double walls ( 7 ) and the floor platforms ( 9 ) have been placed in the sites of the dividing spaces to be made in the floor, the formwork panels ( 14 ) intended for building the space dividing partitions ( 36 ) are vertically arranged on said floor platforms ( 9 ), said formwork panels being fitted in the lugs ( 34 ) and lashed in the bushings ( 35 ), as observed in FIG. 7 , building between two panels ( 14 ) the formwork for building each of the dividing partitions, on the floor platforms ( 9 ) corresponding to the adjacent spaces. The panels ( 14 ) of the adjacent formworks are in turn lashed to one another, such that a rigidly secured formwork is built in the entire floor for all the dividing partitions ( 36 ) to be built.
[0051] The reinforcing framework ( 39 ) for the concrete pouring of the partitions ( 36 ) are placed in the space comprised between the panels ( 14 ) of each formwork, the pipes for the electrical, plumbing and telephone installations, etc. which are provided also being placed in said spaces, and then, by means of supply from the impeller pumps ( 11 ), the openings of the formworks formed by the panels ( 14 ), as well as the inner opening of the double walls ( 7 ) of the outer contour are filled with concrete, whereby forming a rigidly secured assembly between the enclosure of the contour and the interior dividing partitions ( 36 ) in the entire building of the floor, the latter thus being completely finished in its construction, to build thereon another floor or the roof of the building, whichever is appropriate.
[0052] The formwork panels ( 14 ) are provided with mobile parts ( 37 ) which can be displaced to a front projecting position such that a male form can be determined in the formwork between the corresponding parts ( 37 ) of the formwork panels ( 14 ) that are arranged facing one another when building the formworks, as shown in FIG. 12 , for defining the door and/or window openings in the corresponding dividing partitions ( 36 ), such that said openings are also made directly in the constructive building of the floor by means of the formworks.
[0053] The entire functional assembly of the system can be computer-controlled, such that minimal operating and manual collaboration is required, and the process of the construction is very fast and with the quality of an automated implementation with complete precision of the development of the operations according to a programming calculated according to suitability.
[0054] The supporting structure ( 1 ) can vary in shape and size according to the buildings to be built, and can incorporate in the upper part reinforcements ( 38 ), as depicted in FIG. 14 , for increasing its strength and safety, whereas in the upper part and in the entire lateral contour coverings can be arranged for determining an enclosure in which it is possible to work in suitable conditions regardless of the atmospheric conditions which is the cause of losing a great deal of time in conventional constructions. | The invention relates to an automatic system for the construction of buildings, which uses a supporting structure ( 1 ) mounted on displacement rails ( 2 ), covering a space holding the building to be made, the construction taking place floor by floor, in such a way that all the parts of the construction are made in the installation itself, thereby defining a rigidly secured constructive assembly, based on reinforced concrete, in the building of each floor; for this purpose a number of platforms ( 4, 5 ) move in vertical displacement mode on the supporting structure ( 1 ), on which the construction operations are performed at the level of each floor, and include stores ( 3 ) in which the elements used for the construction are held, with a gantry crane ( 10 ) in the upper part for moving the construction elements. | 4 |
TECHNICAL FIELD
This invention relates to an energy control arrangement for a telephone communications system, and more particularly, to an energy saving mode of operation of a communications system which improves the efficiency of operation.
BACKGROUND OF THE INVENTION
A telephone communications system is an on-site call processing system that interconnects a plurality of on-site telephone station sets to other on-site telephone station sets and to a plurality of lines connected to a central office or a private branch exchange. This call processing system generally operates under stored program control and provides a plurality of features to the user, including call forwarding, ability to hold a call, ability to add or drop lines from a conference call and in addition, the basic feature of allowing each station set user to originate and receive station-to-station calls.
To permit full use of these and many additional features of the communications system, the individual station set must provide the user with control access and with information as to its present operational status. This is normally accomplished by use of a multibutton electronic telephone station set having a plurality of push buttons which are used to select modes of operation and a plurality of visual indicator devices, associated therewith, serving to define the present operational status and the line selection.
These visual indicator devices and a DC-to-DC converter included in each station set are normally energized by DC electrical power supplied through the station set telephone line, and generally comprise two LED devices associated with each of the various control buttons of the station set. They are continuously active and consume power of approximately two watts with at least one LED device on, even though the station set is inactive or out of use for a considerable length of time. The most significant inactive period comprises overnight and weekend intervals during which a communications system in a typical business office is often inactive and unused.
In an era of rising energy costs, the dissipation of energy to continuously maintain visual indicator devices active and power inactive station sets during extended intervals of nonuse represents a considerable cost to the subscriber and yet, to deactivate the communications system during off hours to save energy is unacceptable since all stations are denied any off hours use. Given the energy cost reduction desirability and the need of providing continuous normal service to each station set, a practical energy saving control scheme for a communications system must have considerable flexibility to permit full station set service at all times.
A need for every station set in a telephone communication system to be simultaneously powered is an extremely rare event. Accordingly, the power level selected to be supplied may be chosen on the assumption that only a certain percentage of station sets will be used at any one time. However, in those instances where service demand exceeds that level, either the power source is overloaded and a substandard level of power is supplied to each station set or station sets are left to appear dead or malfunctioning with no indication that service is being temporarily denied.
SUMMARY OF THE INVENTION
A stored program energy control system in accord with the principles of the invention is included in a stored program controlled telephone communications system to improve energy efficiency by removing power from the station sets, the visual indicator devices and selected port card circuits during periods of inactivity of the telephone station sets. A scanning and count down routine of the control system identifies station sets that are inactive and disables the application of electrical power thereto. Inactive and de-energized station sets are periodically scanned for service request activity, an occurrence of which is responded to by the energy control system to reapply power to that station set. This energy control system further responds to incoming calls to immediately supply power to the addressed station set. Hence only active station sets are powered, leaving the inactive sets unpowered and thereby improving the overall conference system power efficiency.
With the energy control system in continuous operation, the unpowered state is the natural condition of each individual station set. Each station set remains in that unpowered state until the station set user initiates a service request or an incoming call activates the set. An alternative approach is to have all station sets fully active during normal business hours and utilizing the energy control system only during off hours and weekends.
A further feature of the invention operates to prevent overloading of the power source providing power to the station sets and the port cards associated therewith. According to this feature, once the power demanded by station sets and port cards in operation equals a predetermined power level limit, the application of power to additional station sets and port cards is denied until a presently powered station set becomes inactive. A small amount of power is retained in reserve for supplying an indicating or power busy signal to station sets denied power.
BRIEF DESCRIPTION OF THE DRAWING
An understanding of the operation and nature of this invention may be attained by reference to the following application and accompanying drawing in which:
FIG. 1 shows a functional block schematic of a conference communication system servicing a plurality of multibutton electronic telephone station sets;
FIG. 2 shows a portion of a face plate of a typical multibutton telephone station set;
FIG. 3 shows a flow chart of an overall control scheme for optimizing the energy efficiency of a conference communication system;
FIG. 4 shows a flow chart of a switchhook scan instruction routine;
FIG. 5 shows a flow chart of an incoming call power sequence instruction routine;
FIG. 6 shows a flow chart of a status indicator powering sequence instruction routine for station indicators;
FIG. 7 shows a flow chart of a power down test sequence instruction routine; and
FIG. 8 shows an alternative block schematic arrangement of a conference communication system for applying the principles of the invention to an existing conference communication system utilizing an external energy control unit.
DETAILED DESCRIPTION
A telephone communications system coupling a plurality of individual telephone station sets to a central office or a private branch exchange is shown in FIG. 1. Such a communications system is controlled by instruction routines of a stored program control system to which the energy control instruction routines of the invention may be added or applied. This particular communications system shown in FIG. 1 in block diagram form combines key system telephone features such as line selection, visual status indication, etc. with many other features under control of instructions of the stored program.
A particular illustrative telephone communications system to which the instruction routines of the energy control system of the invention may be applied is disclosed in U.S. Pat. No. 4,109,113 issued Aug. 22, 1978 to C. E. Allison, Jr. et al; U.S. Pat. No. 4,125,748 issued Nov. 14, 1978 to C. E. Nahabedian et al; and U.S. Pat. Nos. 4,150,257; 4,150,259, both of which issued Apr. 17, 1979 to F. M. Fenton et al. These patents, assigned to the same assignee as this application, are all incorporated by reference herein for the description of a stored program controlled communications system having key telephone system features.
Control of call processing in this communications system is under the control of a microprocessor and a stored program in its associated memory system. Each telephone station set 1001 is connected to an interface or line port card circuit 1002, in fact, each line port circuit 1002 handles or services four telephone stations 1001. The port card circuit 1002 is an interface unit which responds to digital control signals on bus 1003, supplied by the central processor 1010, and enables connections between the station sets 1001 and an electronic switching network 1020. In addition, the line port card circuit 1002 includes power connections utilizing tip and ring leads to couple power from a power source to the station set. These power connections are under the control of a relay drive circuit 1004 operative to apply power to the telephone station sets 1001. Alternative means of controlling the application of power to individual station sets may include the use of power supplies mounted directly on the port card which are selectively activated by the central processor or the use of electronic switches in place of relay circuit cards.
Each station set 1001 is scanned through the line port card circuit 1002 to detect changes in status; for example, on hook, off hook, selection of a feature, etc. The memory 1011 of central processor 1010 includes switching control instructions in stored programs included in memory 1011 and translates these detected change of status signals into system commands.
Commands are also generated in response to the subscriber input to the multibutton electronic telephone station set itself. The command operations due to activation of the buttons are accompanied by actuation of the associated visual indicator devices which may be light emitting diodes. A face plate 202 of a typical multibutton electronic telephone set 201 is partially shown in FIG. 2. Each telephone station set 1001 is connected by wire pairs 1007 coming out of the station set 1001 and going to the line port card circuit or interface unit 1002. The line port card circuit 1002 interconnects the tip and ring leads 1007 of the station set to the electronic switching network 1020 and also provides coupling to a data link bus 1003 between the telephone set 1001 and the central processor 1010. The line port card circuit 1002 operates to transmit information from the telephone station set 1001 to the central processor 1010 which, in turn, controls the electronic switching network 1020 and also permits the sending of control signals back to the telephone sets 1001 to operate the particular feature desired and the associated visual indication signals.
The line port card circuit 1002 is also provided with special features which may be connected through the electronic switching network 1020 and through central office interface 1021 to a central office or private branch exchange.
Commands from the central processor 1010 to and from the various station sets are interconnected thereto by a main data bus 1003. Talking and signaling paths go from individual station sets 1001 through the individual port card 1002 via a signaling path 1008 to the electronic switching network 1020 and either to another station set or from thence via a signaling path 1023 through a central office interface 1021 to the central office or another private branch exchange. The central office interface cards 1021 are also connected to receive control signals from the main data bus 1003.
A central control or memory data bus 1013 is included for coupling the central processor 1010 to its memory 1011 and various input/output control circuits which are, in turn, connected to the main data bus.
The operation and control in response to the communications system and to external signals is determined by programmed instructions stored in the system memory 1011. Memory 1011 includes switching control routines and energy control routines. The system memory 1011 is coupled via a memory bus 1013 to a central processor 1010. The memory bus 1013 transfers information into and out of the processor and connects control signals to a variety of interface circuits including an input/output interface circuit 1014 and a network control circuit 1016.
In addition to receiving instructions from the memory 1011, the central processor 1010 receives input from various system sensors coupled via the main data bus 1003 and through the perhiperal circuits which interconnect the main data bus to the memory data bus 1013. The special techniques and details concerning the operation of these data busses and peripherals are well-known to those skilled in the microprocessor art and hence it is believed that these details need not be disclosed herein.
Input/output interface 1014 is a two-way data interface located between the main data bus 1003 and the memory data bus 1013. It performs such functions as coupling data from the memory data bus 1013 to the main data bus 1003. This interface circuit 1014 also includes station address registers and decoders which select and indicate the particular station set port cards 1002 and station sets 1001 to be operated by the central processor 1010. The input/output interface 1014 is connected via the data bus 1003 to the data inputs of the station set port cards 1002, each of which is connected to four individual telephone station sets 1001.
Each station set port card 1002 interfaces four multibutton electronic telephone station sets 1001 with the electronic switching network 1020 via connection 1008. This port card 1002 isolates the electronic switching network 1020 and the data processing circuitry electrically and provides a control powering arrangement by which a voltage applied to the port card 1002 is selectively enabled to be coupled to the station set 1001 in accord with the invention. This voltage is applied to the port card 1002 and coupled through the port card 1002 through controlled switching mechanisms thereon to selected station sets. These switches may be relays operated by a relay drive card, in turn, controlled by information supplied through the main data bus 1003, or the switches may comprise semiconductor switches.
All of the signaling between the station sets 1001 and the port cards 1002 and, eventually the central processor 1010, is performed digitally through the data bus 1003. Power to each individual station set is supplied from a voltage supply source via lead 1009 and a port card 1002 through a control relay and signal lines 1007 to the station set 1001 by phantom techniques. Phantom techniques are well-known to those skilled in the telephone art, and a detailed explanation is not necessary to explain this operation.
Talking paths are via the signal lines 1007 from each individual station set 1001 to the port card 1002 and subsequently through a signaling line 1008 to the electronic switching network 1020. Electronic switching networks are well-known in the telephone art and hence it is not believed necessary to disclose it in detail herein. The electronic switching network 1020 is also controlled in response to the central processor 1010 via the network control interface 1016. Signaling lines 1018 from the electronic switching network 1020 are connected through central office interface cards 1021 also controlled by the central processor 1020 through the main data bus 1003. The central office interface cards 1021 each of which handles four bidirectional lines are coupled to outgoing lines 1023 coupled, in turn, to a central office.
In operation, a control signal from the central processor 1010 is coupled through the network control interface 1001 which connects the memory data bus 1013 to the main data bus 1003. This process controls the switching network connections by sending control words over the memory bus 1013 and the switching data bus 1022 to cause selected connects and disconnects therein to occur.
A typical front panel or face plate of a multibutton electronic telephone station set 201 as partially shown in FIG. 2 includes a multibutton electronic dialer 213, and a plurality of data selection and line selection buttons 214. Accompanying each of the selection buttons 214 are two visual indicator lights 211 and 212 embodied herein as light emitting diodes. These selection buttons 214 include system access buttons 210, a hold button 215, and a plus/minus button 216. System access buttons 210 are labeled to identify each set extension number in the conference system and provide lines through which both inside and outside calls may be connected. The system access buttons 210 may be used in combination with the other buttons to enable a variety of features, such as holding a call, adding parties to a call, dropping parties from a call, or transferring the call to another station. As indicated, each system access button has associated with it two light emitting diodes operating as visual indicators to indicate the status of a line selection or other status features. A complete explanation of the various features of the above described communications system may be found in the patents incorporated hereinabove by reference, and hence the detailed description therein need not be repeated.
The status indicator lights 211 and 212 have been continuously operated with the station set being continuously powered in the prior art versions of this communications system. This continuous operation represents a significant power dissipation, and in accord with the principles of this invention, a control instruction routine added to the memory 1011 operates through the switchhook sense cards 1050 and the relay drive cards 1004 of FIG. 1 to achieve a reduction in this energy dissipation in each of the individual multibutton electronic telephone station sets 1001. To this end, the energy saving control instructions interact with the actual status and operation of the communications system to selectively de-energize the visual status indicators, the selection buttons, and all associated circuitry within the multibutton electronic telephone sets during time intervals when their use is not essential. In particular, energy savings are achieved by controlling the phantom power applied to each multibutton electronic telephone station set 1001 and by also controlling power applied to the station set port cards 1002. Energy consumption is reduced by turning off any or both of these circuits when not needed to process calls. This turning off of energy supplied to these circuits is referred to herein as power down of the circuits. In contrast to continuously operate these station sets 1001, and port cards 1002 as in the prior art causes a considerable consumption of power. It has been found in the illustrative embodiment that powering down a station set 1001 when not in use saves two watts of input power. By powering down the associated station set port card 1002, an additional half watt can be saved.
The energy saving arrangement using the power down technique described herein does not interfere for practical purposes with normal operations of the conference communication system. The only apparent affect is the lack of visual status indicators and selection button response during nonoperation of the individual station sets 1001. Otherwise, all of the communications system features described in the patents incorporated herein by reference are fully retained and normal operation utilizing these features is available to each station set 1001. Hence if any one of the station sets 1001 connected to a port card 1002 requires power, its associated port card 1002 cannot be powered down unless all of the station sets, connected to a particular port card are inactive. Since each station set 1001 has a variety of needs, their power down state or the supply of power thereto is controlled on the basis of its individual needs. Where an auxiliary controller is added to supply energy control to an existing prior art communications system, as described hereinbelow with reference to FIG. 7, certain services to the station sets are granted a higher priority than other services. For example, power to a station set to receive an incoming call has the highest priority. The next priority is granted when it is necessary to energize a visual indicator on the station set to show the status of certain features of the communications system. A lessor priority requiring power is when a user goes off hook on a station set. This particular condition represents the lowest priority request for power; however, the response to the system is so fast compared to response times of human senses, that the normal ordering of these priorities in their effect is not apparent to the user.
Power down instructions are included in the overall energy control instructions included in the memory 1011 and are utilized by the control processor to achieve power savings. The power down or power processing instructions control the application of power to various port cards and station sets in order to limit power dissipation in the context of a normally operating conference communications system. The power down and energy control instructions recognize selected call activity, such as the station set switchhook state, incoming calls, and status information, to determine when it is necessary to reapply power to the appropriate port card 1002 or station set 1001 so that the features are continuously available for use at each station set.
The nature of this control system may be best explained by examining, in detail, the flow charts of the various control instructions included in the memory 1011 to control the processing of energy including power down within the communications system. The instruction routines to achieve energy efficiency include a main energy control loop, a specific power down routine to de-energize the station sets and port cards; a routine to detect switchhook activity at the individual station sets; a routine to detect incoming calls and a routine to apply power to energize the port cards and station sets. The normal state of a station set is its power down state. Switchhook activity and incoming calls re-energize the station set until a power down state resumes upon the completion of call activity. The latter three of these routines all re-energizes the station set from its normal powered down state while the first routine makes a decision to power down a station set.
Under direction of the instruction routines of the energy control arrangement, all the station sets 1001 are normally in a powered down condition until a use demand is generated. The instruction routine continually operates to either maintain a power down condition to sense a use demand and activate the station set. If a use demand results that a station set be powered, power is applied and control is returned to the normal instruction control of the central processor for normal switching and call processing.
The basic overall instruction routine flow chart for attaining improved power efficiency is shown in FIG. 3. This routine responds to conditions that result in power being applied to an individual station set or a particular port card, and it also performs a check that permits power down to be implemented. This instruction routine is normally entered in the terminal symbol 9002 or via interrupts generated by incoming calls as shown by the subroutine in FIG. 5 or by a need for multiple status indication as shown by the subroutine of FIG. 6. The instruction routine is initialized in process symbol 9004. This entails determining and entering into the routine preliminary factors such as the number of station sets in the communications system, the number of sets that can be adequately powered and similar information.
The instruction routine flow proceeds to process symbol 9008 whose instructions scan all station sets for a change in switchhook status (i.e., on hook to off hook and vice versa). In instances where a change from off hook to on hook is determined, the routine proceeds to process symbol 9012 which places the affected station set on a power down queue in which a routine described below evaluates the station set to see if it is appropriate to remove power from it. If a change from on hook to off hook has occurred, the routine proceeds to decision symbol 9016 which initiates a power-up sequence and determines if the capacity of the system power supply will be exceeded if this station set is supplied power. The functions performed in process symbols 9001, 9012 and 9016 are detailed in the switchhook scan routine shown in FIG. 4.
After completion of switchhook scan, the instruction routine proceeds to process symbol 9020 which identifies the station sets in a queue waiting for power up. These sets are powered up in a power-up sequence instruction in process symbol 9024.
The basic routine next investigates the station sets suitable for power down in process symbol 9026 and executes the power down in process symbol 9028. These functions are detailed in the routine of FIG. 6. Following process symbol 9026, the basic routine loops via flow line to process symbol 9008 and the whole routine is repeated.
A switchhook scan routine is disclosed in FIG. 4. This routine is executed by the central processor in the illustrative embodiment every 25 milliseconds and operates to scan the switchhook status of every individual station set 1001. Switchhook status is determined by scanning all of the switchhook sensor circuits 1050 shown in FIG. 1. These switchhook sensor circuits 1050 may comprise a voltage sensor to respond to the open circuit condition when the station set is on-hook. The switchhook scan routine is entered at terminal symbol 3002 in FIG. 4. Instructions according to process block 3004 cause the central processor to read the present on-hook or off-hook status of every station set in blocks of station sets associated with each switch sense circuit. The instruction routine proceeds to decision symbol 3006 whose instruction determines if the switchhook status of each and every station set has changed since it was polled during the previous run of the switchhook activity routine. If the decision is that no switchhook states have changed, the instruction routine proceeds to process symbol 3008, whose instruction directs that the next group of station sets be covered by a next switchhook scan circuit. The routine then proceeds to decision symbol 3010 whose instruction determines if the last group of station sets have been polled for off-hook. If such is the case, the instruction routine proceeds to terminal symbol 3012 and returns to the main routine of FIG. 3 and if not, the routine proceeds to process symbol 3004.
If a station set has gone off-hook, the instruction routine proceeds from decision symbol 3006 to process symbol 3014 whose instructions identify the particular station set whose status has changed. Instructions of the subsequent decision symbol 3016 determine if the change of the station set status has been from off-to-on-hook or from on-to-off-hook. If the transition has been from off-to-on-hook, the routine proceeds to process symbol 3018 whose instructions update a status word in memory indicating the switchhook status of each station set. If the transition has been from on-hook to off-hook, the instruction routine proceeds to decision symbol 3020.
Decision symbol 3020 represents instructions that determine if the station set just gone off-hook is powered. If it is already, the instruction routine proceeds directly to process symbol 3022 whose instructions are discussed below. If the station set is not powered, the routine proceeds to decision symbol 3030 whose instructions determine if powering this particular station set would cause the power output capacity of the power supply 1000 supplying voltage to the communications system in FIG. 1 to be exceeded. This evaluation of exceeding power capacity is termed herein as power busy, meaning that a preset power output capacity not to be exceeded would be exceeded if another power load is added. If power is not busy, the routine proceeds to decision symbol 3024 whose instructions determine if the port card, associated with the station set has been powered. If the port card is not powered, the routine proceeds to process symbol 3026 whose instructions direct application of power to the port card and from thence, the routine proceeds to process symbol 3028.
If the port cards are powered, the routine proceeds from decision symbol 3024 to process symbol 3028 whose instructions direct that power be applied to the station set. The instruction routine then continues to process symbol 3022.
The power down count referred to in process symbol 3022 is a count value maintained in memory for each station set. A station set, according to the program, must be on hook with a status indicator engaged to satisfy the initialization of the power down routine discussed below. The power down count assures that a certain timed interval of nonuse occurs before the set is powered down. The instruction of process symbol 3022 initializes the power down count to some value, then assumes that the station set will not be powered down until the power down count is fully decremented. After the power down count is initialized, the instruction routine proceeds via process symbol 3018 and 3008 to decision symbol 3010, which is discussed above.
If the power busy determination of decision symbol 3030 has indicated that power supply capacity is about to be exceeded, the routine proceeds to decision symbol 3032 to determine if the station set is on the power-up queue. If it is not, the process symbol 3034 instruction places it on the queue. The routine proceeds to process symbol 3036, following either a yes decision in decision symbol 3032 and following process symbol 3034, to provide a power busy signal to the off-hook station set to indicate to the user that service cannot be provided.
Incoming calls require that individual station sets be immediately re-energized. This is accomplished with the incoming call detector routine shown in FIG. 5. This routine is an interrupt driven routine which responds to the detection of an incoming call by the central processor controlling the electronic switching network. As soon as an incoming call is detected, this call detection routine is initiated as an interrupt routine and is entered at terminal symbol 4002. Subsequent instructions of process symbol 4006 identify the address of the station set recipient of the incoming call and the instructions of process symbol 4008 reads a status word indicating the operative state of that particular station set and which is presently contained in the memory. The status word is used by the instructions of decision symbol 4010 to determine if the station set is already powered. If the station set is already powered, the call detection routine is exited at terminal symbol 4014.
If the station set is not powered, the call detection routine proceeds to decision symbol 4030 which determines if sufficient power capacity is available to power the station set. If power capacity is not sufficient, decision symbol 4032 and process symbols 4034 and 4036 operate to provide a power busy signal to the station set and the routine continues directly to return terminal 4014. If available power capacity is sufficient, the detection routine proceeds to decision symbol 4016 whose instruction determines if the associated port card is powered. If the port card is powered, the routine proceeds to power the station set via the instruction of the process symbol 4020. If it is not, the port card is first powered by the instruction or process symbol 4018.
After the station set is powered, the instruction of process symbol 4022 updates the status word to indicate the current status of the newly powered station set. The call detection routine then proceeds via process symbol 4012 to the return terminal symbol 4014.
When a station set goes off hook or has an incoming call resulting in powering the station set or when some status LED must be energized to indicate a conference system feature such as message waiting or call forwarding, the appropriate visual indication must be powered to indicate status to the user. The instruction routine to power this visual indication is called by an interrupt signal responsive to the central processor applying power to the station set.
The first step of the status indicator routine shown in FIG. 6 is to identify the address of the individual station set activated as per process symbol 5004. Having identified the station set, its status word is read as directed by the instruction of process symbol 5006 and utilized in decision symbol 5008 to determine if the station set is powered or not. If it is, the instruction routine proceeds to process symbol 5018 whose instructions reinitialize the power down count and the instruction routine terminates at terminal symbol 5020.
If the station set is not powered, the instruction routine proceeds to decision symbol 5030 to determine if power supply capacity is sufficient to supply power to the station set. If power capacity is insufficient, a power busy signal is generated in response to instructions of process symbol 5036 and the routine proceeds to process and return symbols 5018 and 5020.
If the power supply capacity is sufficient, the control system is placed in a wait state by instructions of process symbol 5010 and instructions of subsequent decision symbol 5012 determines if the port card is powered. If it is not, power is supplied by the instruction of process symbol 5014 and the routine continues to process symbol 5016 as it does also if the answer to decision symbol 5012 had been yes. The instructions of process symbol 5016 supply power to the station set, and its status word is brought up to date in response to instructions of process symbol 5022 wherein the routine continues via process symbol 5018 to the terminal symbol 5020.
The chief objective of the energy control arrangement is to power down individual station sets whenever they are inactive. In the illustrative embodiment herein, a station set is powered down if it has been inactive for 5 seconds. An inactive station set is defined as a station set that is on-hook with only one status indicator light activated. The powering down of this station set is accomplished by the power down instruction routine shown in FIG. 7 which is part of the main routine of FIG. 3 and which operates once every 25 milliseconds to check every station set for inactivity.
The power down routine of FIG. 7 is entered at terminal symbol 6002 and proceeds to process symbol 6004 whose instructions call for monitoring of a first station set to determine if it is inactive. A subsequent instruction shown by process symbol 6006 decrements the power down count associated with that station set. As indicated above, the power down count associated with each station set is set by periods of activity and is periodically decremented by the routine to assure that a definite interval of inactivity has elapsed before it is powered down. The routine then proceeds to decision symbol 6008 whose instructions determine if the count down value is zero or nonzero; that is, whether the prerequisite interval of inactivity has elapsed.
If the power down count is not zero, the routine proceeds to process symbol 6010 whose instructions direct that the power down routine consider the next station set for power down consideration. Subsequent decision symbol 6012 inquires if all station sets have been considered; if not, the power down count in the next station set is decremented as instructed by process symbol 6006, and the routine proceeds to decision symbol 6008 as described above. If all the station sets have been covered, the routine is terminated at terminal symbol 6020.
If the instructions of decision symbol 6008 have determined a particular power down count to be zero, the subsequent instructions of process symbol 6014 turn off the power as applied to that particular station set. Instructions of subsequent decision symbol 6016 inquires if all station sets attached to the same port card are turned off. If they are, subsequent instructions of process symbol 6018 turn off power supplied to the port card. If the port card has powered station sets or after the process symbol 6018, the routine proceeds to process symbol 6010 whose activity has been discussed above.
It is apparent from the foregoing description that in the normal mode of operation, all station sets and all port cards are in a power down state until a demand for service occurs. This arrangement permits the powering down of this element of the system without significantly interfering with the normal operation of the telephone communication system. In a system embodying the invention comprising 15 station sets and 5 port cards, measurements indicated energy savings of up to 45% improvement over the standard operating energy drain.
Because of the substantial energy savings that can be achieved, it is desirable that these methods be applied to existing telephone communication systems that operate under a stored program control. Applications of these principles to an existing telephone communications system can be achieved by implementing power down control with an external processor acting in cooperation with the existing stored program control for the telephone system.
A control system permitting the implementation of power down control to an existing telephone communications system is shown in FIG. 8. In this telephone system, an auxiliary control 701 includes an auxiliary processor 702, memory 703 and interface 704. This interface is connected to the central processor 7010 of the control of the conference system and to a call detect sensor 705 and switchhook sensor 706. The call detect sensor 705 is coupled to receive signals responsive to incoming calls and provide an interrupt, the auxiliary processor 702 which puts the central processor in a wait state while the called station set is powered.
The memory 703 of the auxiliary control 701 includes the powering and power down instruction routines discussed above with reference to FIGS. 3, 4, 5, 6 and 7, which operate to effectively modify the operation of the conference system to achieve energy savings without effectively changing the operation of the central processor. When a power down or powering routine is called for, the central processor 7010 is placed in a wait state while the appropriate energy saving routines are being processed. Upon completion, control is returned to the central control of the conference system.
Since the central control of the conference system services all station sets sequentially, the circuitry controller must be synchronized to the central controller. Then synchronization is achieved by using timing signals of the central processor.
For example, the central control system will detect incoming calls and identify the address of the called station set, placing it on the central control bus. The auxiliary processor picks up the call detection signal of sensor 705 as an interrupt signal to initiate the call detection routine and the address from the bus is utilized to direct the application of power to the proper station set.
The detection of switchhook activity is accomplished by a series of switchhook sense circuits 706 which are coupled to a voice path of the station set to develop and on/off status signal. Station indication information follows call detection, and the central processor 7010 sends station information to the called station set. The auxiliary processor senses this information through sensor 706 to activate the station indication powering routine. Hence the energy savings routine of the invention may be applied to existing conference communication systems without the necessity of modifying their instruction routines. | A stored program energy control system operates with the control of a telephone communications system to improve its energy efficiency by removing power from station sets and their associated visual indicators when they are inactive. Inactive station sets are identified by establishing minimal intervals of nonuse to define the inactive status. The energy control system responds to events like incoming calls and switchhook activity to restore power to the station set. Since energy is applied to a station set only when precisely needed, the overall energy drain of the system is greatly reduced. | 8 |
BACKGROUND
[0001] Modern software systems are exceedingly complex. Development of a software system incorporates activities such as project planning, resource planning, release management, build management, stream management, and the like. Further adding to this complexity, the teams involved in any given software development project are routinely located in geographically different locations. Managing this complexity requires a comprehensive view of the availability and skills of the resources involved.
BRIEF SUMMARY
[0002] One or more embodiments disclosed within this specification relate to software development.
[0003] An embodiment can include a method. The method can include selecting a task defined within a project plan of a software system under development, wherein the task specifies a development tool and a user, and automatically authorizing, using a centralized data processing system, the user to access the development tool.
[0004] Another embodiment can include a system. The system can include a processor configured to initiate executable operations. The executable operations can include selecting a task defined within a project plan of a software system under development, wherein the task specifies a development tool and a user, and automatically authorizing the user to access the development tool.
[0005] Another embodiment can include a computer program product. The computer program product can include a computer readable storage medium having stored thereon program code that, when executed, configures a processor to perform executable operations. The executable operations can include selecting a task defined within a project plan of a software system under development, wherein the task specifies a development tool and a user, and automatically authorizing the user to access the development tool.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
[0006] FIG. 1 is a block diagram illustrating a software development environment 100 in accordance with an embodiment disclosed within this specification.
[0007] FIG. 2 is a block diagram illustrating an exemplary implementation of the project plan execution system (PPES) 105 of FIG. 1 in accordance with another embodiment disclosed within this specification.
[0008] FIG. 3 is a flow chart illustrating a method of project planning in accordance with another embodiment disclosed within this specification.
[0009] FIG. 4 is a flow chart illustrating a method of project planning in accordance with another embodiment disclosed within this specification.
DETAILED DESCRIPTION
[0010] As will be appreciated by one skilled in the art, aspects of the present invention may be embodied as a system, method or computer program product. Accordingly, aspects of the present invention may take the form of an entirely hardware embodiment, an entirely software embodiment (including firmware, resident software, micro-code, etc.) or an embodiment combining software and hardware aspects that may all generally be referred to herein as a “circuit,” “module” or “system.” Furthermore, aspects of the present invention may take the form of a computer program product embodied in one or more computer readable medium(s) having computer readable program code embodied, e.g., stored, thereon.
[0011] Any combination of one or more computer readable medium(s) may be utilized. The computer readable medium may be a computer readable signal medium or a computer readable storage medium. A computer readable storage medium may be, for example, but not limited to, an electronic, magnetic, optical, electromagnetic, infrared, or semiconductor system, apparatus, or device, or any suitable combination of the foregoing. More specific examples (a non-exhaustive list) of the computer readable storage medium would include the following: an electrical connection having one or more wires, a portable computer diskette, a hard disk drive (HDD), a solid state drive (SSD), a random access memory (RAM), a read-only memory (ROM), an erasable programmable read-only memory (EPROM or Flash memory), an optical fiber, a portable compact disc read-only memory (CD-ROM), a digital versatile disc (DVD), an optical storage device, a magnetic storage device, or any suitable combination of the foregoing. In the context of this document, a computer readable storage medium may be any tangible medium that can contain, or store a program for use by or in connection with an instruction execution system, apparatus, or device.
[0012] A computer readable signal medium may include a propagated data signal with computer readable program code embodied therein, for example, in baseband or as part of a carrier wave. Such a propagated signal may take any of a variety of forms, including, but not limited to, electro-magnetic, optical, or any suitable combination thereof. A computer readable signal medium may be any computer readable medium that is not a computer readable storage medium and that can communicate, propagate, or transport a program for use by or in connection with an instruction execution system, apparatus, or device.
[0013] Program code embodied on a computer readable medium may be transmitted using any appropriate medium, including but not limited to wireless, wireline, optical fiber, cable, RF, etc., or any suitable combination of the foregoing. Computer program code for carrying out operations for aspects of the present invention may be written in any combination of one or more programming languages, including an object oriented programming language such as Java™, Smalltalk, C++ or the like and conventional procedural programming languages, such as the “C” programming language or similar programming languages. The program code may execute entirely on the user's computer, partly on the user's computer, as a stand-alone software package, partly on the user's computer and partly on a remote computer, or entirely on the remote computer or server. In the latter scenario, the remote computer may be connected to the user's computer through any type of network, including a local area network (LAN) or a wide area network (WAN), or the connection may be made to an external computer (for example, through the Internet using an Internet Service Provider).
[0014] Aspects of the present invention are described below with reference to flowchart illustrations and/or block diagrams of methods, apparatus (systems), and computer program products according to embodiments of the invention. It will be understood that each block of the flowchart illustrations and/or block diagrams, and combinations of blocks in the flowchart illustrations and/or block diagrams, can be implemented by computer program instructions. These computer program instructions may be provided to a processor of a general purpose computer, special purpose computer, or other programmable data processing apparatus to produce a machine, such that the instructions, which execute via the processor of the computer, other programmable data processing apparatus, or other devices create means for implementing the functions/acts specified in the flowchart and/or block diagram block or blocks.
[0015] These computer program instructions may also be stored in a computer readable medium that can direct a computer, other programmable data processing apparatus, or other devices to function in a particular manner, such that the instructions stored in the computer readable medium produce an article of manufacture including instructions which implement the function/act specified in the flowchart and/or block diagram block or blocks.
[0016] The computer program instructions may also be loaded onto a computer, other programmable data processing apparatus, or other devices to cause a series of operational steps to be performed on the computer, other programmable apparatus or other devices to produce a computer implemented process such that the instructions which execute on the computer or other programmable apparatus provide processes for implementing the functions/acts specified in the flowchart and/or block diagram block or blocks.
[0017] One or more embodiments disclosed within this specification relate to software development. In accordance with the inventive arrangements disclosed within this specification, a project plan is developed that specifies one or more tasks relating to the development of a particular software system. The tasks can specify particular information such as what is to be done, who is to perform the task, when the task is to be performed, and the particular development tool or tools to be used in completing the task.
[0018] A project plan execution system can access the project plan and determine the particular users that require access to development tools to perform the tasks. As used within this specification, the term “user” refers to a human being. The project plan execution system can provide users with access to the development tools necessary for each respective user to complete the task(s) assigned to the user as needed. The project plan execution system provides users with access to the development tools in an automated manner thereby reducing the burden of manually configuring the development tools. Similarly, the project plan execution system ensures that a user's ability to access a development tool responsive to completion of a task or another predetermined condition being met is discontinued.
[0019] FIG. 1 is a block diagram illustrating a software development environment 100 in accordance with an embodiment disclosed within this specification. Within this specification, the term “development” is used to refer to activities including “software development,” “software maintenance,” “application lifecycle management,” or the like. As such, the term “development” encompasses any tasks involved in, or part of, creating (developing) a software system, maintaining a software system, and/or application lifecycle management.
[0020] As pictured, software development environment 100 can include a project plan execution system (PPES) 105 coupled to one or more development tools 110 , 115 , and 120 via a network 125 . For purposes of illustration, each of the PPES 105 and development tools 110 - 120 can represent a data processing system that is operable to execute program code. As such, each of PPES 105 and development tools 110 - 120 can execute an operating system and an application that, taken together, configure each of the aforementioned blocks to perform the executable operations described within this specification. In one aspect, PPES 105 is a centralized data processing system such as a server.
[0021] It should be appreciated that PPES 105 and each of development tools 110 - 120 can represent a single data processing system or a collection of two or more data processing systems. For example, each development tool can be embodied as one data processing system or a collection of two or more interconnected data processing systems. In another example, however, two or more development tools can be embodied as a single data processing system.
[0022] Network 125 can represent any of a variety of communication networks or a combination of two or more communication networks coupled together. For example, network 125 can be implemented as, or include, a Wide Area Network, a local area network, a wireless network, a mobile network, the Internet, or various combinations thereof, to which data processing systems, communication devices (including mobile devices), and the like can be coupled.
[0023] Development tools 110 - 120 represent any of a variety of different development tools found within a software development environment. Examples of different varieties of development tools can include, but are not limited to, a project planning system, a resource planning system, a source code control system, a build and release system, a distribution system, or the like. In general, each of development tools 110 - 120 represents a particular development tool to which one or more users must be granted access from time to time in order to complete tasks delegated to that user as part of a project plan such as project plan 130 .
[0024] As pictured, project plan 130 can be provided to PPES 105 . A “project plan” refers to a collection of one or more tasks that must be performed to complete a specific software development project relating to the development of a software system. Examples of tasks can include development of source code for the software system, correcting defects in the software system, generating builds of the software system, stream (e.g., version) management and/or integration for the software system, test execution, build execution, image distribution, etc.
[0025] FIG. 1 illustrates an example of a task, referred to as “Task 1 ,” that can be included within project plan 130 . As shown, Task 1 specifies an action that is to be performed (e.g., the “what” that is to be performed), a user (e.g., a developer) assigned to the task, a development tool to be utilized by the user in performing the task, one or more rights to be granted to the user within the development tool, and a time span during which the user is to perform the task and, therefore, have access to the development tool associated with the task. The user, for example, is to be granted the rights specified within the task in the development tool in order to complete the task (or action specified by the task). Other parameters that can be included or specified as part of a task within project plan 130 can include a role for the user to be assumed in performing the task.
[0026] In one example, a supervisor or project planner can create project plan 130 using available planning tools. Responsive to releasing project plan 130 to PPES 105 , PPES 105 can execute project plan 130 by identifying unfinished tasks, determining which developers are to have access to particular development tools for tasks, automatically establishing access for the developers with the development tools, configuring the development tools to provide users with the rights specified within the tasks, monitoring for task completion, and automatically discontinuing access for the developers upon expiration of the time span during which the developer is to have access to the development tool or responsive to completion of the task with which the developer is associated.
[0027] Consider the case in which task 1 specifies a particular action that requires usage of development tool 110 by user 135 . For purposes of illustration, it can be assumed that each user, e.g., user 135 and/or user 140 , interacts with software development environment 100 by way of a data processing system, e.g., a client. Accordingly, reference to a user also refers to the particular data processing system through which the user interacts with one or more other components of software development environment 100 .
[0028] In any case, PPES 105 can ensure that user 135 has access to development system 110 for the time span specified in task 1 . For example, PPES 105 can configure development tool 110 to provide the rights specified by task 1 to user 135 for the time span specified by task 1 . Similarly, project plan 130 can include another task, e.g., task 2 (not shown), that indicates that user 140 is to be provided access to development system 110 for a different time span that may overlap with the time span of task 1 or that is completely disjoint from the time span of task 1 . In either case, PPES 105 can ensure that user 140 is provided with the appropriate rights within development system 110 for the time span as specified by task 2 .
[0029] The example above is provided for purposes of illustration. It should be appreciated that PPES 105 can interact with one or more or all of development tools 110 - 120 in order to configure each respective system with access rights for one or more users involved in performing tasks in project plan 130 . Further, PPES 105 can continue to operate over the lifetime of the software development project corresponding to project plan 130 to continue facilitating access to development tools for users and removing that access when necessary as described within this specification.
[0030] FIG. 2 is a block diagram illustrating an exemplary implementation of the PPES 105 of FIG. 1 in accordance with another embodiment disclosed within this specification. Like numbers will be used to refer to the same items throughout this specification.
[0031] PPES 105 can be include at least one processor 205 coupled to memory elements 210 through a system bus 215 or other suitable circuitry. As such, PPES 105 can store program code within memory elements 210 . Processor 205 can execute the program code accessed from memory elements 210 via system bus 215 . In one aspect, for example, PPES 105 can be implemented as a computer that is suitable for storing and/or executing program code. It should be appreciated, however, that PPES 105 can be implemented in the form of any system including a processor and memory that is capable of performing the functions and/or operations described within this specification.
[0032] Memory elements 210 can include one or more physical memory devices such as, for example, local memory 220 and one or more bulk storage devices 225 . Local memory 220 refers to RAM or other non-persistent memory device(s) generally used during actual execution of the program code. Bulk storage device(s) 225 can be implemented as a hard disk drive (HDD), solid state drive (SSD), or other persistent data storage device. PPES 105 also can include one or more cache memories (not shown) that provide temporary storage of at least some program code in order to reduce the number of times program code must be retrieved from bulk storage device 225 during execution.
[0033] Input/output (I/O) devices such as a keyboard 230 , a display 235 , and a pointing device 240 optionally can be coupled to PPES 105 . The I/O devices can be coupled to PPES 105 either directly or through intervening I/O controllers. One or more network adapters 245 also can be coupled to PPES 105 to enable PPES 105 to become coupled to other systems, computer systems, remote printers, and/or remote storage devices through intervening private or public networks. Modems, cable modems, and Ethernet cards are examples of different types of network adapters 245 that can be used with PPES 105 .
[0034] As pictured in FIG. 2 , memory elements 210 can store a project plan execution engine 250 . Project plan execution engine 250 , being implemented in the form of executable program code, can be executed by PPES 105 and, as such, can be considered part of PPES 105 . Accordingly, project plan execution engine 250 , when executed, configures PPES 105 to perform the various functions and executable operations described within this specification.
[0035] FIG. 3 is a flow chart illustrating a method 300 of project planning in accordance with another embodiment disclosed within this specification. Method 300 can be implemented using the PPES 105 as described with reference to FIGS. 1 and 2 (hereafter “system”).
[0036] Method 300 can begin in block 305 where a project plan can be loaded into the system. In block 310 , the system can determine users and development tools that are specified by one or more tasks included within the project plan. In block 315 , the system can authorize each user specified by a task with the particular development tool, or development tools as the case may be, also specified by the task.
[0037] Authorization for a user with a particular development tool can be performed in a variety of different ways. In one aspect, the system can access an interface of a development tool to interact with the development tool directly. In that case, the system can effectively log into the development tool and access an account of the user to which access is to be provided. The system can configure the development tool to provide the user with the necessary access to the development tool in the form of one or more rights according to the task.
[0038] In another aspect, the system can generate temporary tokens that, when in possession of a user (e.g., the data processing system of the user), provide the user with access to one or more development tools. Accordingly, a “token based” development tool refers to a development tool that permits access to the development tool according to whether the data processing system of a user includes or has stored a token.
[0039] In one embodiment, the token is a bearer token that acts as a credential for purposes of authenticating the user to the development tool or development tools. A bearer token refers to a digital object that is presented to an entity, e.g., a verifying entity such as a development tool, in an authentication transaction. In the case of a bearer token, the bearer token need not be bound to a particular identity. Rather, the mere possession of the bearer token by a data processing system authorizes the user (the data processing system of the user) for particular activities. In another embodiment, the token is not a bearer token and, as such, requires authentication or verification by the system.
[0040] FIG. 4 is a flow chart illustrating a method 400 of project planning in accordance with another embodiment disclosed within this specification. Method 400 can be implemented using the PPES (system) 105 as described with reference to FIGS. 1-3 of this specification.
[0041] In block 405 , the system can load the project plan. Once loaded, the system can begin execution of the project plan. For example, the system can continually monitor the current date and/or time and to identify tasks that require processing. In block 410 , the system can identify tasks from the project plan that require access to a development tool. For example, the system can identify any task that specifies that a user is to be provided with access to a development tool.
[0042] In block 415 , the system can determine, or identify, whether any tasks exist within the project plan that specify a time span that begins within a predetermined amount of time into the future. It should be appreciated that block 415 need only operate upon, or search, those tasks identified in block 410 . In illustration, the system can be configured to detect tasks indicating that a user is to be provided access to a development tool for a time span that has a start time that occurs within the next five minutes, within the next hour, within the next 24 hours, or the like. In one aspect, the predetermined amount of time into the future used to detect the start time of a time span for a task can be configurable as a system parameter and/or can be specified on a per task basis.
[0043] If the system identifies one or more tasks, method 400 can continue to block 420 . If not, method 400 can continue to block 450 . Continuing with block 420 , the system can select a task identified in block 415 . In block 425 , the system can determine whether the development tool is a token based. If so, method 400 can proceed to block 430 . If not, method 400 can continue to block 440 .
[0044] In block 430 , the system can generate one or more token(s) for user(s) associated with the particular task that is being processed. In one aspect, the system can generate a token for a token based system that specifies an expiration date and/or time that is set according to the time span of the task. Thus, the token can expire when the time span expires or completes. The system further can generate a token that specifies the particular rights that are to be afforded to a user when the user logs into the development environment using the token. Thus, in an embodiment in which a token is generated, the system need not login to the development tool to configure rights for the user. The time span for which the user is granted access to a particular development tool and the rights afforded to that user are specified through the token that is generated by the system.
[0045] In one embodiment, the information specified by the token is encoded within the token itself. In another embodiment, the information specified by a token is not stored within the token itself. Rather, the token is correlated with the task for which the token was generated and need not specify information directly. In that case, when a development tool is provided with a token from a user, the development tool can access the system to determine the particular rights associated with the token and the time span for which the token is valid, e.g., whether the token is expired. In any case, a control layer, or some other integration path, between the development tools and the system can be established over which the development tools can validate a received token.
[0046] It should be appreciated that the example provided is for purposes of illustration only and is not intended as a limitation of the one or more embodiments disclosed within this specification. In another embodiment, the token can be encoded with partial information with any additional information being obtained from the system using a correlation maintained between the token and the task for which the token was created as described.
[0047] In block 435 , the system can provide the token to the user. The token can be provided through any of a variety of different methods such as via electronic mail, via a download or other manner of file access, or the like. After block 435 , method 400 can proceed to block 450 .
[0048] In block 440 , in the case where the development tool is not token based, the system can directly interact with the development tool to authorize the user to access the development tool. In one aspect, the system can be provided with a level of access, e.g., administrative access, to one or more development tools via an exposed interface of the development tool(s). The system can interact directly with each respective development tool through the exposed interface of that development tool. The system, in effect, logs into the development tool as an administrative user with rights to change access rights of other users (human developers).
[0049] In block 445 , the system can authorize the user to access the development tool. The system can configure the development tool to provide the user with the access, e.g., the one or more rights, as enumerated by the task. For example, the system can set or enable the rights, per the task, for an account of the user that is associated with the task within the development tool. In cases where the development tool permits the system to specify a time span for which the rights are valid, the system can do so. Otherwise, the system can monitor the status of the task as described within this specification and de-authorize the user as appropriate. After block 445 , method 400 can proceed to block 450 .
[0050] In block 450 , the system can determine whether the time span for any task has expired. The time span for a task expires when the end time of the time span specified within the task has passed (e.g., is in the past). The system further can determine whether any of the tasks for which the time span has not expired have been completed. If so, method 400 can continue to block 455 . If not, method 400 can proceed to block 415 to continue processing.
[0051] In block 455 , the system can de-authorize access to a development tool for a user as specified by the particular task or tasks identified in block 450 . In one aspect, the particular development tools for which users are de-authorized are those that are not of the token based variety. As such, the system logs into the development tools and removes or disables the rights previously provided for the user account within the development tools.
[0052] In another aspect, in the case of a token based development tool that contacts the system for authentication of a token, the system can de-authorize access for a given user from a task or tasks identified in block 450 by not authenticating the token to the development tool. Otherwise, e.g., as in the case of a bearer token, when the token expires, the bearer of that token loses access to the particular development tool for which the token was generated and/or issued without any further involvement by the system.
[0053] The one or more embodiments disclosed within this specification provide techniques for leveraging project and resource planning to automatically implement development tool access modifications so that projects can continue to run smoothly. The one or more embodiments disclosed within this specification are provided for purposes of illustration and are not intended as limitations. Other variations are also contemplated. For example, the project plan can be updated through the addition of new tasks, deleted tasks, or modified tasks. The system can execute the plan as it continues to evolve for a given software development project.
[0054] The flowchart and block diagrams in the Figures illustrate the architecture, functionality, and operation of possible implementations of systems, methods and computer program products according to various embodiments of the present invention. In this regard, each block in the flowchart or block diagrams may represent a module, segment, or portion of code, which comprises one or more executable instructions for implementing the specified logical function(s). It should also be noted that, in some alternative implementations, the functions noted in the block may occur out of the order noted in the figures. For example, two blocks shown in succession may, in fact, be executed substantially concurrently, or the blocks may sometimes be executed in the reverse order, depending upon the functionality involved. It will also be noted that each block of the block diagrams and/or flowchart illustration, and combinations of blocks in the block diagrams and/or flowchart illustration, can be implemented by special purpose hardware-based systems that perform the specified functions or acts, or combinations of special purpose hardware and computer instructions.
[0055] The terminology used herein is for the purpose of describing particular embodiments only and is not intended to be limiting of the invention. As used herein, the singular forms “a,” “an,” and “the” are intended to include the plural forms as well, unless the context clearly indicates otherwise. It will be further understood that the terms “includes,” “including,” “comprises,” and/or “comprising,” when used in this specification, specify the presence of stated features, integers, steps, operations, elements, and/or components, but do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, components, and/or groups thereof.
[0056] Reference throughout this specification to “one embodiment,” “an embodiment,” or similar language means that a particular feature, structure, or characteristic described in connection with the embodiment is included in at least one embodiment disclosed within this specification. Thus, appearances of the phrases “in one embodiment,” “in an embodiment,” and similar language throughout this specification may, but do not necessarily, all refer to the same embodiment.
[0057] The term “plurality,” as used herein, is defined as two or more than two. The term “another,” as used herein, is defined as at least a second or more. The term “coupled,” as used herein, is defined as connected, whether directly without any intervening elements or indirectly with one or more intervening elements, unless otherwise indicated. Two elements also can be coupled mechanically, electrically, or communicatively linked through a communication channel, pathway, network, or system. The term “and/or” as used herein refers to and encompasses any and all possible combinations of one or more of the associated listed items. It will also be understood that, although the terms first, second, etc. may be used herein to describe various elements, these elements should not be limited by these terms, as these terms are only used to distinguish one element from another unless stated otherwise or the context indicates otherwise.
[0058] The term “if” may be construed to mean “when” or “upon” or “in response to determining” or “in response to detecting,” depending on the context. Similarly, the phrase “if it is determined” or “if [a stated condition or event] is detected” may be construed to mean “upon determining” or “in response to determining” or “upon detecting [the stated condition or event]” or “in response to detecting [the stated condition or event],” depending on the context.
[0059] The corresponding structures, materials, acts, and equivalents of all means or step plus function elements in the claims below are intended to include any structure, material, or act for performing the function in combination with other claimed elements as specifically claimed. The description of the embodiments disclosed within this specification have been presented for purposes of illustration and description, but are not intended to be exhaustive or limited to the form disclosed. Many modifications and variations will be apparent to those of ordinary skill in the art without departing from the scope and spirit of the embodiments of the invention. The embodiments were chosen and described in order to best explain the principles of the invention and the practical application, and to enable others of ordinary skill in the art to understand the inventive arrangements for various embodiments with various modifications as are suited to the particular use contemplated. | Automatic authorization of users and configuration of a software development environment can include selecting a task defined within a project plan of a software system under development, wherein the task specifies a development tool and a user, and automatically authorizing, using a centralized data processing system, the user to access the development tool. | 6 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application relates to and claims priority from U.S. Provisional Patent Application Ser. No. 61/747,649, filed Dec. 31, 2012.
FIELD OF THE INVENTION
[0002] An improved cutting blade is disclosed. In a preferred embodiment, the improved blade has two-fold rotational symmetry and sharpened, hook shaped cut-outs at the leading edges. These sharpened hook-shaped cut-outs serve to improve cutting efficiency not only by slicing, rather than chopping, through the grass as it cuts, but also by lowering the moment of inertia of the rotating blade and thereby reducing the energy needed to spin the lawn mower blade. The hook-shaped cut-outs may be added to any existing lawn mower blade design. In a second preferred embodiment, the improved blade has upturned sections on the trailing edges. These upturned edges serve to guide grass clippings up and out of the mower.
BACKGROUND OF THE INVENTION
[0003] There is a basic deficiency in the design of rotary mowers. It lies in the blade design and, in particular, in the way in which standard blades attack the grass. The angle of attack is extremely inefficient, as it is more like a chopping action than a slicing action. This can be appreciated when considering cutting with a kitchen knife. Slicing, or stroking the blade edge across the material to be cut, accomplishes the task of cutting with great energy savings over classic chopping, or driving the edge through the material to be cut in a straight downward stroke.
[0004] The following patents and published applications illustrate efforts of others to address some of the problems identified and solved by the disclosure herein. As can be seen, these efforts fall short of providing a complete solution to the problems confronted and solved by the instant disclosure.
[0005] These references include: U.S. Pat. No. 7,299,612, entitled “Rotary Mower Blade,” issued to Schuyler on Nov. 27, 2007; U.S. Pat. No. 6,470,662, entitled “Multiple Blade Cutting Apparatus for Rotary Lawn Mower,” issued to Burke et al. on Oct. 29, 2002; U.S. Pat. No. 6,415,591, entitled “Lawn mower Blade with Fan Structure for Creating Enhanced Air Movement,” issued to Tylka, Sr. on Jul. 9, 2002; U.S. Pat. No. 5.899,053, entitled “Lawn Mower Blade,” issued to Roth on May 4, 1999; U.S. Pat. No. 5,394,612, entitled “Brush and Weed Cutter Blade,” issued to Wolfington on Mar. 7, 1995; U.S. Pat. No. 5,343,68, entitled “Cutter Blade for a Rotary Cutter,” issued to de Jong on Sep. 6, 1994; U.S. Pat. No. 4,995,228, entitled “Cutting Blade for Rotary Cutting Machinery,” issued to Hladik, Jr. on Feb. 26, 1991; U.S. Pat. No. 4,628,672, entitled “Rotary Cutter,” issued to Jones on Dec. 16, 1986; U.S. Pat. No. 3,447,291, entitled “Detachable Mower Blade,” issued to Guetterman on Jun. 3, 1969; U.S. Pat. No. 3,343,355, entitled “Lawn Mower Blade,” issued to Freedlander et al. on Sep. 26, 1967; U.S. Pat. No. 3,214,896, entitled “Rotary Cutter Blade,” issued to Watkins et al. on Nov. 2, 1965; U.S. Pat. No. 3,022,621, entitled “Blade for Rotary Cutter,” issued to Zavarella on Feb. 27, 1962; U.S. Pat. No. 2,850,862, entitled “Cutting Device,” issued to Asbury on Sep. 9, 1958; U.S. Pat. No. 1,407,417, entitled “Cutter,” issued to Huelves on Feb. 21, 1922; U.S. Design Pat. No. D523,028, entitled “Rotary Blade,” issued to Fitzpatrick on Jun. 13, 2006; U.S. Design Pat. No. D502,185, entitled “Cutter Blade,” issued to Byrne on Feb. 22, 2005; World Intellectual Property Organization Application Publication No. WO 2003 096786 A1, entitled “Rotary Lawn Mower Blade,” published on behalf of Besogne on Nov. 27, 2003.
[0006] These references are discussed in greater detail as follows.
[0007] U.S. Pat. No. 7,299,612 generally discloses a rotary motor blade which has a rotational mounting structure in its body member to mount the blade to a power driven motor and thereby rotate the blade. The body member includes at least one free end extending outwardly of the mounting structure with the free end having a front leading edge and a rear trailing edge interconnected by a tip. At least a portion of the front leading edge is tapered to comprise a cutting edge. At least one and preferably a plurality of air flow deforming elements such as indentations are formed in the front leading edge and extend inwardly from the exposed outer surface of the front leading edge to disturb air flow along the rotating blade and enhance the creation of vortices which allow the flow to go from the front leading edge to the rear trailing edge. In a preferred practice of the invention, the air flow deforming elements are a plurality of indentations formed in the front leading edge. Each indentation has a blunt (i.e. unsharpened) exposed surface at the front leading edge. Generally, the overall shapes of the leading (sharpened) edges are shown as straight but no overall shape is claimed, except in regard to the airflow deforming elements. (Claims 1, 15; FIGS. 4, 7, 8)
[0008] U.S. Pat. No. 6,470,662 generally discloses a blade cutting apparatus for a rotary lawn mower. The blade cutting apparatus is defined by a plurality of blades projecting radially outward from a central hub. Each blade is defined by a first portion and a second portion, the first portion being defined by a first edge and a second edge and the second portion being defined by a third edge and a fourth edge. The first and third edges are each sharpened for enabling each blade to cut grass in two separate locations along the length of each strand of grass. Each blade is further defined by an elongated slot formed therein between the first portion and the second portion for allowing cut grass and debris to pass through each blade. While the cutting edges of the blades are shown as either convexly or concavely curved, only a convexly curved sharpened edge is claimed. (FIGS. 1a, 1b, 2; Claim 1).
[0009] U.S. Pat. No. 6,415,591 generally discloses a lawn mower blade for cutting grass with a scything action. The lawn mower blade includes an elongated bar. The bar is adapted to engage a drive shaft of a lawn mower. The bar has a generally arcuate first cutting edge. The first cutting edge extends along a first side edge of the bar proximate a first end of the bar to a distal end of a second side edge of the bar. The bar further has a generally arcuate second cutting edge. The second cutting edge extends along the second side edge of the bar proximate a second end of the bar to a distal end of the first side edge of the bar. While the leading sharpened edge of the blade is arcuate, the Figures show a convexly curved leading sharpened edge (FIG. 1).
[0010] U.S. Pat. No. 5,899,053 generally discloses a lawn mower blade with an improved cutting edge to produce a more efficient cutting area. The inventive device includes an elongated blade member, a first scalloped cutting edge region on one end of the blade member, a second scalloped cutting edge region on the other end, a first deflecting fin on the opposite edge of the second scalloped cutting edge region, a second deflecting fin on the opposite edge of the first scalloped cutting edge region, and a mounting means for mounting the blade member to a lawn mower. The new lawn mower blade is designed to increase the surface area of the cutting edge to effectively cut grass more cleanly and evenly even than a conventional rotary lawn mower blade. The leading sharpened edge of the blade is generally straight, but has a series of scallops to increase the cutting area (FIGS. 1, 3, 5).
[0011] U.S. Pat. No. 5,394,612 generally discloses a cutter blade which has a body portion with a central attaching hole for removable attachment to an output end of a powered tool. The blade has a pair of oppositely extending ends with beveled cutting edges on their leading edges. The body and end portions of the blade are curved upwardly for increasing the efficiency in the cutting operation of the blade. It is preferred that the radius of curvature of the blade be approximately 30 inches and that the sharpening bevels on the leading edges extend from a point adjacent the mid-point of the blade to the tips of the blade. The cutting edges are progressively narrower from the mid-point to the tips for increased cutting efficiency and blade strength. The cutter blade also has clearance bevels on the lower surface thereof at the trailing edges of the end portions. These clearance bevels extend from an inner area of the body portion short of the mid-point of the blade to the respective tips. The cutting edges are generally convexly curved (FIGS. 1, 2, 4).
[0012] U.S. Pat. No. 5,343,681 generally discloses a cutter blade for use on a rotary cutter of the tractor drawn type. The cutter blade of the invention has a convexly curved cutting edge with the section including the cutting edge being off-set with respect to the section where the blade is mounted on its blade carrier. The ratio of the radius of the circle and the length of the cutting section is between 2:1 and 15:1. The ratio of the overall flat bar length to the length of the cutting section may be between 2:1 and 4:1, whereas the ratio of the overall flat bar length to the flat bar width may be approximately 5:1. Still further, the thickness of the flat bar may be between 5 mm and 15 mm. The use of such cutter blades on a rotary cutter improves cutting efficiency, provides for an increased blade life and reduces the power requirements of the rotary cutter with which the blades are associated (FIGS. 2, 3, 4; Claim 1).
[0013] U.S. Pat. No. 4,995,228 generally discloses a rectangular metallic plate cutting blade having an opening at the center thereof for attaching the plate to a rotary power shaft. A pair of trapezoidally-shaped cutting recesses is cut into the leading edges of the blade. The edges of the plate defining the cutting recesses are beveled to provide sharp cutting edges. The several cutting edges are individually straight but collectively function to provide an improved cutting action being achieved through a gathering and slicing action. A turbulence flange extends upwardly from the trailing edge of the metallic plate on the opposite side of the plate from each of the trapezoidally-shaped cutting recesses. Each of these turbulence flanges is from about 1.0 to about 1.5 times as long as the width of the trapezoidally-shaped recess with which it is aligned across the blade, and defines an angle of from about 35° to about 55° with respect to the major plane of the rectangular plate (claim 1; FIGS. 1, 2).
[0014] U.S. Pat. No. 4,628,672 generally discloses an improved cutter that finds principal utility in, but is not limited to, lawn mowers of the type in which a cutter blade is rotated about an upright axis by a power source such as an electric motor, internal combustion engine, etc. The disclosed improvement involves a blade that produces a slicing rather than a shearing action, accomplished by a blade design having diametrically opposed end portions, each sharpened to provide a convexly curved slicing edge that is directed from a leading edge portion to a trailing edge portion, thus providing a blade of increased efficiency and requiring lower consumption of horsepower. The slicing edges may also be combined with conventional impact cutting edges. Further, the slicing edge is fashioned or configured to occur as a minimum within the radial distance from the outermost extremities of the blade an amount equal to the maximum exposure of the rotating blade to uncut grass that is encountered with each revolution of the blade as the mower is moved through the grass in a plane parallel to the plane of blade rotation. This radial distance can be defined by a formula relating the radial distance to: the travel velocity of the mower, the number of cutting ends on the blade and revolutions per minute of the rotating blade (Column 1, lines 25-53; FIGS. 1-6).
[0015] U.S. Pat. No. 3,447,291 generally discloses a cutter blade for removable disposition within a socket provided in the cutter arm or blade support of agricultural equipment designed for mowing, which blade is provided with female portions for reliably engaging cooperating male members within the socket. At its outer end, the operational portion of blade A is curved forwardly for enhancing the cutting action by direction of the grass or grain to be cut. This results in a slightly concave cutting surface (Column 2, lines 71-71; Column 3, line 1; FIGS. 1, 2).
[0016] U.S. Pat. No. 3,343,355 generally discloses an improvement over prior invented lawn mower blades in that the same curved shape is retained, but at the same time the cutting arms of the blade are also curved in a plane at right angles to the shaft, somewhat in the shape of a scimitar. The blade terminates in two arms which are curved oppositely from each other in a plane at right angles to the shaft, terminating in rounded tips. It has been found that this shape enhances the cutting action of the blade by permitting the cutting surface to strike the blades of grass at an angle, thus providing a slicing action. The cutting edge of the blade is curved convexly. The blade is manufactured entirely of a flexible urethane elastomer material (Column 2, lines 6-10; Column 2, lines 38-40, FIG. 3; Claims 1 and 4).
[0017] U.S. Pat. No. 3,214,896 generally discloses a rotary cutting blade which has a leading edge which is indented by a plurality of semi-circular hollow ground cutting edges, the adjacent semi-circular cutting edges being spaced by unindented portions of the leading edge (Column 1, lines 21-24; FIG. 1).
[0018] U.S. Pat. No. 3,022,621 generally discloses a rotary blade which cuts by forming an indented cutting edge or edges on the side of the blade at an angle greater than 90° to the direction of rotation of the blade. The cutting edge indentations are grouped in a straight line alignment across the cutting path (Column 1, lines 49-53; Column 2, lines 29-30; FIGS. 1 and 3).
[0019] U.S. Pat. No. 2,850,862 generally discloses an invention which relates to cutting devices, and is particularly concerned with a cutter blade and an arrangement for supporting the cutting blade on a rotary holder therefor. It is also an object of the invention to provide a swingable type cutter element for lawn mowers or lawn edgers, or the like, in which a sickle cutting action is had thereby improving the cutting efficiency of the cutting element. The outer end of the longer leg 15 of the cutting element is concave in the direction of rotation of holder 10 and the edge of the concave portion is sharpened as indicated at 30, so as to provide for a sickle cutting action (Column 1, lines 15-18 and lines 38-42; Column 2, lines 41-44; FIG. 3).
[0020] U.S. Pat. No. 1,407,417 generally discloses improvements in cutters for use in machines for picking up, cutting and plowing under cane straw and the like, the object of the invention being to effect improvements in the construction of the cutters, especially as to the shape of the arms thereof to adapt the cutters for picking up the straws or stalks to be cut, and also as to the construction and arrangement of the cutter blades. Each cutter blade corresponds in shape with the cutter arm to which it is attached, and has a curved hook-shaped outer end (Column 1, lines 10-19; Column 2, lines 89-92; FIGS. 1, 2, 4).
[0021] U.S. Design Pat. No. D523,028 generally discloses a design for a rotary cutter. The rotary cutter has 3 curved arms. One edge of each arm is convexly curved and one edge of each arm is concavely curved (FIGS. 1, 2, 4).
[0022] U.S. Design Pat. No. D502,185 generally discloses a design for a cutter blade. The blade has two arms. One edge of each arm is straight and the other is convexly curved (FIGS. 1-3).
[0023] PCT Appl. Publication No. WO 2003 096786 A1 generally discloses a lawn mower blade or the like consisting of a rectangular elongated and flattened plate (2) including in its center a bore (3) bordered on either side with holes (4) for its being fixed to a rotating drive shaft, said blade comprising a leading edge (7), a trailing edge (8) and a raised part (9) located proximate each end of the blade, while each leading edge (1) and trailing edge (8) has, relative to a horizontal, plane containing the plate (2), a chamfered profile (6) which is provided with an angle (β) ranging between 0 and 30 degrees and in that the chamfered profile (6) includes a tapered terminal tip (10) whereof the land thickness d ranges between 0.1 and 0.5 millimeters. The leading edge is shown as straight or as having a concave cut-out (FIGS. 1, 4).
[0024] Thus, a problem associated with blades that precede the present disclosure is that they do not provide, in combination with the other features and advantages disclosed herein, a blade that slices, rather than chops, through grass to be cut.
[0025] Still a further problem associated with blades that precede the present disclosure is that they do not provide, in combination with the other features and advantages disclosed herein, a blade that cuts efficiently and is therefore especially suited for use in battery powered lawn mowers, which tend to have limited use time between charges and thus will more freely benefit from extended run times with a more efficient blade design.
[0026] Another problem associated with blades that precede the present disclosure is that they do not provide, in combination with the other features and advantages disclosed herein, a blade that has a reduced moment of inertia, thus requiring less energy to rotate the same at a given rate of speed.
[0027] There is a demand, therefore, to overcome the foregoing problems while at the same time providing an improved cutting blade that can be readily manufactured and maintained.
SUMMARY OF THE INVENTION
[0028] In a preferred embodiment, the rotary lawn mower blade disclosed herein provides an improved cutting edge. The improved cutting edge may be applied to any existing typical lawn mower blade. The improved cutting edge comprises a sharpened, arc-shaped cut-out at the outer end of the rotating blade that cuts grass with a slicing, rather than chopping motion. This slicing motion not only is more efficient, resulting in lower power consumption by a rotary lawn mower using the improved blade, but also can be sharpened to a more keen edge than prior art blades. This keener, hollow ground edge, combined with the slicing action, results in the grass being cut cleanly, rather than torn off. The cut edges of the grass thus are not as prone to die and turn brown as is the case with prior art blades that chop, rather than slice, the grass.
[0029] Further, the disclosed improved blade, having cut-outs near its outer ends, has a reduced mass at its outer ends, furthest from its axis of rotation, thus reducing the moment of inertia of the blade compared to a blade without the cut-outs. The lower moment of inertia of the blades is anticipated to contribute to a lower power consumption during lawn mowing, making the improved blade especially suited for use in electric, battery-operated lawn mowers where reduced power consumption translates to additional square footage of lawn that can be mowed per battery charge.
[0030] The following disclosure provides an improved rotary lawn mower blade that provides the foregoing advantages while at the same time is economical to manufacture.
BRIEF DESCRIPTION OF THE DRAWINGS
[0031] In the detailed description that follows, reference will be made to the following figures:
[0032] FIG. 1 illustrates a prior art cutting blade adapted for use on a lawn mower;
[0033] FIG. 2 is a perspective view of a preferred embodiment of an improved cutting blade;
[0034] FIG. 3 is a front view of the preferred embodiment shown in FIG. 2 ;
[0035] FIG. 4 is a front view of a second preferred embodiment;
[0036] FIG. 5 is a cross-sectional view of the cutting edge of the preferred embodiment shown in FIG. 2 ;
[0037] FIG. 6 is a schematic of a section of the preferred embodiment shown in FIG. 2 ;
[0038] FIG. 7 is perspective view of a second preferred embodiment of an improved cutting blade; and
[0039] FIG. 8 is a cross-sectional view of a portion of the second preferred embodiment shown in FIG. 7 .
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
[0040] Introduction:
[0041] There is a basic deficiency in the design of rotary mowers. It lies in the blade design and, in particular, in the way in which standard blades attack the grass. The angle of attack is extremely inefficient, as it is more like a chopping action rather than a slicing action. This can be appreciated when considering work with a kitchen knife. Slicing, or stroking the blade edge across the material to be cut, accomplishes the task of cutting with great energy savings over classic “chopping,” or driving the edge through the material to be cut in a straight downward stroke.
[0042] A chopping motion is the cutting approach used by all current rotary mowers. Their cutting edges are driven into the material, much as one drives an axe into a tree trunk. This inefficiency is demonstrated in analogous fashion by two different mandolin slicers; one having a blade edge extending perpendicular to the stroke of the material across the slicer and the other having a blade edge extending about 30 degrees off of perpendicular to the stroke of the materials across the slicer. The angled blade is more efficient.
[0043] Just as a vegetable in the kitchen, grass can be cut much more efficiently if the blade is stroked across the grass, the cutting edge attacking it at an angle to the radius of the spinning blade rather than parallel to the radius. This cutting technique in mowing grass is demonstrated in the use of the classic scythe. A skilled user mowing with a scythe can cut with a smooth, efficient, manual stroke. According to Wikipedia, the scythe dates back to about 500 B.C.
[0044] While energy savings would be realized in both a gasoline-powered mower and a battery-powered mower, the range of mowing ability in gasoline-powered mowers is typically adequate for most consumers' needs. Conversely, the battery charge capacity for cordless battery-powered mowers is too limited at present for many homeowners. Consequently, in a most preferred embodiment, it is anticipated that the technology disclosed herein will be more readily applied for use on a battery-powered mower. The improved cutting edge disclosed herein may be adapted to any existing lawn mower blade design.
[0045] The simplest method of adapting the current disclosure to a rotary mower is to take an existing mower blade design and modify the cutting edge area as follows. The cutting edge area would be modified from a straight line into an arc that brings the line of the cutting edge nearest the tip as close to parallel to the circle the tip of the blade makes spinning in the deck of the mower, and progressively arcing back to the pre-existing edge cut nearer the center of the length of the blade. Most rotary mower blades have an upward bend of the trailing edge of the blade end to propel the grass clippings upward into the deck and out through the chute to the bagging attachment or discharge chute. Accommodations either in the scythe arc modification or the clippings control bend may variously be included, depending on the details of the specific blade to be modified with the disclosed improved cutting edge.
[0046] Further, the arc-shaped cut-outs at the blade's ends reduce mass furthest from the blade's axis of rotation, thus reducing significantly the moment of inertia of the spinning blade. This reduces the energy needed to accelerate the blade to a set rotational speed, further contributing to the efficiency of the improved cutting blade.
[0047] In a preferred embodiment, a 14-inch battery-powered electric mower (Neuton EM 4.1 battery electric mower manufactured by Neuton, Inc. Vergennes, Vt.) is used. Developmental data was acquired on a 120 foot by 60 foot city/suburban lot. Allowing for buildings, pavement and planting beds, the lot provided about 3000 square feet of lawn. This is typical of suburban homes in the United States, particularly those that are proximate to major cities such as New York or Chicago.
[0048] Comparing the conventional, but sharpened, blade to the prototype of the current disclosure, the mower was operated over two (as near as possible) identical patches of lawn, each having a thick growth of grass on them. The sound of the mower motor with the prototype blade (with the as yet un-hardened edge) was much less complex, of a significantly higher dominant pitch and was more constant throughout mowing the thicker patches of grass, as compared to the sound of the mower using the standard blade doing the same work. It is anticipated that the higher pitch, less complex, more constant sound observed during mowing through relatively heavy material indicates that less load is placed on the motor using the prototype blade than using the conventional blade during the accomplishment of similar mowing work. It is further anticipated that an even greater reduction in operational load will be attainable upon hardening and re-dressing, or sharpening with an extra fine grit stone, the prototype's cutting edge to the greater, more durable keenness it will allow.
[0049] Description of Figures:
[0050] A typical, prior art, rotary lawn mower blade 10 , as shown in FIG. 1 , cuts grass with a chopping motion. When the blade is rotated, the cutting surfaces 20 move rotationally and meet the grass in a perpendicular relation. Consequently, the cutting surfaces 20 are driven into the grass, much as one drives an axe into a tree trunk. This inefficiency is demonstrated in analogous fashion by two different mandolin slicers; one having a blade edge extending perpendicular to the stroke of the material across the slicer and the other having a blade edge extending about 30 degrees off of perpendicular to the stroke of the materials across the slicer. The angled blade is more efficient because the blade is sliced across the grass, resulting in the cutting edge attacking it at an angle to the radius of the spinning blade rather than parallel to the radius.
[0051] A first preferred embodiment of a cutting blade 100 modified according to the current disclosure adapted for use on a lawn mower is shown in FIG. 2 . The blade 100 is comprised of any suitable metal, e.g. steel or the like. The blade 100 is configured to be mounted under the deck 200 of a rotary lawn mower as shown in in FIG. 3 .
[0052] Referring now again to FIG. 2 , the blade 100 comprises an elongated member 102 having nominal length L, nominal width W and nominal thickness t. A typical length L may be between 14 and 24 inches. A typical width W may be between 2 and 4½ inches. A typical thickness t may be between 1/10 inch and ¼ inch. Each of L, W and t may vary within a given blade 100 , as uniformity is not required. However, rotational symmetry is required for rotational balance.
[0053] The blade 100 has a top side 104 , which is understood to be the side facing lawn mower deck 200 . Blade 100 has ends 106 and sides 108 . A mounting hole 110 is centrally placed equidistant from the ends 106 and the sides 108 of blade 100 and must be positioned at the center of mass of the blade 100 . The direction of rotation of the blade 100 is shown by the arrows and the blade 100 possesses two-fold rotational symmetry about the mounting hole 110 .
[0054] Looking in more detail at FIG. 2 , it can be seen that blade 100 has a modified cutting region 120 at each terminus 112 , with a mounting area 124 in the central portion of the blade 100 .
[0055] The modified cutting regions 120 are flat and co-planar to each other. Although not necessary, as drawn the cutting regions 120 are parallel to but below (relative to the mower deck 200 ) the mounting area 124 . Thus, because the mounting area 124 can either be flat (as shown in FIG. 4 ) flat or raised (as shown in FIG. 3 ), the mounting area 124 is preferably between 0 and ¾ inch above the modified cutting regions 120 . More preferably, the mounting area 124 is between 0 and ⅝ inch above the modified cutting regions 120 . In a most preferred embodiment, the mounting area 124 is between 0 and ½ inch above the modified cutting regions 120 .
[0056] Shoulder regions 126 are interposed between the mounting area 124 and the modified cutting regions 120 , and are sloped as necessary to provide a 1:2 rise, i.e. the horizontal component of the shoulder region preferably is about twice the length of the vertical component of the rise, and are preferably twice as long as the height of the raised mounting area.
[0057] Blade 100 also has two sharpened cutting edges 128 . These sharpened cutting edges 128 are positioned so that, in operation, when the blade 100 rotates in the direction indicated by the arrows, the sharpened cutting edges 128 are at the leading edges of the blade 100 .
[0058] On a modified 14-inch Neuton blade prototype, the total length of each cutting edge 128 is about 4 inches. On a conventional, 21-inch long Sears mower blade, the total length of each cutting edge is about 7 inches. As shown, however, a curved slicing region of the cutting edge 128 is provided and is preferably between 2 and 2½ inches long. In a most preferred embodiment, the curved slicing region of the cutting edge 128 is 2¾ inches long.
[0059] As shown in front cutaway in FIG. 3 , the mounting hole 110 provides an aperture through which the blade 100 can be removably secured in drivable relation to a lawn mower engine or motor 132 . The lawn mower engine or motor 132 rotates the blade 100 . This removable securement can be achieved through traditional apparatus such as bolt 134 and nuts 136 . The mounting hole 110 may be of any suitable size to accept the bolt 134 and the mounting hole 110 is understood to be the axis about which blade 100 rotates. It is understood that other mounting arrangements are possible; for instance, two symmetrically located mounting holes may be used to mount the blade 100 to an engine or motor 121 , but the blade 100 would still rotate about its center of mass.
[0060] Also shown in FIG. 3 , the mounting area 124 and shoulder regions 126 combine to ensure that as blade 100 is rotated by the engine or motor 132 around the mounting hole 110 , the modified cutting region 120 is below and clear of the lawn mower deck 200 as the blade 100 rotates and cuts grass 36 . Of course, this arrangement is only one example of a construction by which the lawn mower blade 100 is maintained clear of the lawn mower deck 200 as the blade 100 rotates. For example, the blade 100 may not include distinct shoulder regions 126 where the mounting area 124 and the modified cutting region 120 are coplanar (i.e. the rise is 0 inches). Thus, the blade 100 may be mounted onto a lawn mower engine or motor 132 by bolt 134 and nuts 136 , as shown in FIG. 4 . It is understood here as well, that a single bolt is only one of the possible arrangements by which the blade 100 can be secured in drivable relation to the motor or engine 132 .
[0061] FIG. 5 illustrates a cross-sectional view of blade 100 taken along line A-B in FIG. 2 . FIG. 5 shows in larger view the profile of a preferred shape of sharpened cutting edge 128 . The sharpened cutting edge 128 is hollow ground, with the concave side oriented towards the top side 104 of the blade 100 . The included angle θ of the hollow ground sharpened cutting edge 128 is preferably between 20 and 30 degrees. The preferred edge angle φ is between 0 and θ degrees, and more preferably 15 degrees.
[0062] Referring now to FIG. 6 , the sharpened cutting edge 128 that extends into the modified cutting region 120 is shown in more detail. Terminus 140 of sharpened cutting edge 128 extends into modified cutting region 120 and further has a hook-shaped slicing edge 138 . The hook-shaped slicing edge 138 comprises an arc-shaped edge 142 and an angled straight edge 144 . The arc-shaped edge 142 is located at the outer terminus of the blade 100 and is adjacent the angled straight edge 144 , which is positioned closer to the mounting hole 110 in the center of blade 100 . The arc-shaped edge 142 has a radius of curvature R. Radius R is preferably between ⅝ and 1¼ inches, and more preferably ¾ inches. Radius R extends into the modified cutting region 120 such that the narrowest part of the modified cutting region 120 , N, is between 55 and 85 percent of W and most preferably 70 percent of W.
[0063] The angled straight edge 144 is positioned at an angle β as it extends tangentially from the arc-shaped edge 142 . Preferably β is between 5 degrees and 20 degrees, and more preferably is between 10 degrees and 15 degrees, as measured from the side 108 of blade 100 . Further, the arc-shaped edge 142 extends between 120 and 150 degrees of arc, and preferably extends 135 degrees. The angled straight edge 144 has length s which depends on distance needed to intersect both the side 108 of blade 100 and the arc-shaped edge 142 . The length s is preferably between 0.5 and 1 inches, and more preferably 0.8 inches. Accordingly, the total length of the hook-shaped slicing edge 138 is between 2 inches and 2½ inches and most preferably is 2¼ inches.
[0064] Also shown in FIG. 6 , a tip 146 of the arc-shaped cutting edge 138 is provided. The radius of arc-shaped edge 142 is placed such that the tip 146 is formed from the intersection of the arc-shaped cutting edge 138 with the outer end 106 of blade 100 . As illustrated, the tip 146 is shown as a sharp point, but it is expected that a production model would be preferably slightly rounded, in order to provide more strength.
[0065] The outer end 106 of the blade 100 intersects the side 108 of the blade 100 at angle ω, as shown in FIG. 6 . The angle ω is preferably 100 degrees and ranges from 90 degrees to 110 degrees.
[0066] A second preferred embodiment of the blade 100 is shown in perspective view in FIG. 7 . Like the first embodiment of the blade 100 , this embodiment also possesses two-fold rotational symmetry about the mounting hole 110 . This second embodiment is similar to the first embodiment, except that the modified cutting region 120 further comprises an upturned section 148 and a notch 152 , both located on the trailing edge of blade 100 . The notch 152 is located at the intersection of shoulder region 126 and modified cutting region 120 . The upturned section 148 is bent upward towards the top 104 of blade 100 at an angle α, along the line C-D shown in FIG. 7 . Angle α is preferably 10 degrees, but may range from 5 degrees to 15 degrees. The line C-D runs substantially parallel to the centerline of blade 100 and is distance M from the trailing edge of blade 100 . Distance M is preferably 30% of width W, but may range from 25% to 35 percent of W. The notch 152 is of depth M, such that the upturned section 148 may be bent independently of the shoulder region 126 , ensuring that the remaining section of modified cutting region 120 remains coplanar with raised mounting area 124 .
[0067] FIG. 8 is a cross section of FIG. 7 , taken along the line E-F in FIG. 7 , showing the angle α and distance M. Upon rotation, upturned section 148 provides airflow to direct grass clippings upwards and away from blade 100 .
[0068] in operation, the lawn mower engine or motor 132 will spin the blade 100 at a typical rotational rate of 2000 to 4000 revolutions per minute. Assuming that the lawn mower is propelled forward at 3 feet per second and that the lawn mower blade is spinning at 3000 revolutions per minute, the lawn mower travels forward 0.05 feet or 0.6 inches per revolution. Thus, it is believed that the blade 100 slices, rather than chops, the grass, and that the hook-shaped slicing edge 138 gathers grass as it is sliced. Further contributing to the efficiency of the improved modified blade, the hook-shaped cut-outs at the blade's ends reduce the mass furthest from its axis of rotation, thus reducing the moment of inertia of the blade.
[0069] As thus described, an improved lawn mower blade is disclosed. The improved blade possesses two-fold rotational symmetry about a center mounting hole. The improved blade comprises a hook shaped slicing edge at the leading edge of its outer ends. The hook-shaped slicing edge comprises an arc shaped edge at the very outer terminus of the leading edge, connected to an angled straight edge. The angled and curved shape of the cutting edges contributes to a slicing, rather than chopping motion through the grass as the blade spins. This slicing motion improves the efficiency of the blade as it cuts grass, so that less energy is used. The hook-shaped cut-out also reduces the mass of the improved blade furthest from its axis of ration, reducing the moment of inertia and thus the energy needed to spin the blade. Further, the cutting edge of the improved blade is hollow ground and therefore is sharper than a straight-ground blade which also contributes to the efficiency of the improved blade. The improved blade may further comprise an upturned section on the trailing edges of the slicing section, which directs grass clippings up and away from the blade. It is anticipated that this hook-shaped slicing edge can be applied to any existing lawn mower blade design.
[0070] The described embodiments are to be considered in all respects only as illustrative and not restrictive, and the scope of the invention is, therefore, indicated by the appended claims rather than by the foregoing description. Those of skill in the art will recognize changes, substitutions and other modifications that will nonetheless come within the scope of the invention and range of the claims. | An improved blade is disclosed. The blade has an elongated member having rotational symmetry about a center axis. The elongated member further has two ends each having a sharpened edge, wherein at least a portion of each sharpened edge comprises a slicing edge configured to intersect a stalk of grass in non-perpendicular relation. The blade is configured so that rotation of the blade causes the slicing edges to come into non-perpendicular contact with the grass, thereby slicing the grass to be mowed. | 0 |
CROSS-REFERENCE TO RELATED APPLICATIONS
This patent application is the U.S. national phase, under 35 USC 371, of PCT/EP2004/051995, filed Sep. 1, 2004; published as WO 2005/023690 A1 on Mar. 17, 2005, and claiming priority to DE 103 40 569.0, filed Sep. 1, 2003, the disclosures of which are expressly incorporated herein by reference.
FIELD OF THE INVENTION
The present invention is directed to methods for the reduction of register errors on a web of material passing through a printing nip in a multi-color web-fed rotary printing press, and to devices for accomplishing that reduction in register errors. A deformation is established between an area of the web intermediate its edges, and areas in the vicinity of the edges of the web.
BACKGROUND OF THE INVENTION
Register errors can occur when printing, in a positionally correct manner, from several serially-positioned printing formes, and particularly in the course of color printing. In this case, the web of material passes successively through several printing groups, in which groups the web is imprinted, respectively, in several colors. If these colors are not imprinted exactly on top of, or one after each other in the desired way, because of such variables as a varying module of elasticity of the web of material, a varying tension profile of the web of material, because of climatic influences or because of production tolerances of the printing forme cylinders, this inaccuracy is called register error.
The extent of a register error can be a function of its position in the lateral direction of the web. If this function is imagined as being developed as a Taylor series, it can be seen that, in general, the register error is composed of a term of zero order, which is independent of the lateral position, a term of the first order, which is proportional to the position in the lateral direction, and terms of higher orders. The term of zero order, such as, for example a register error, over the entire width of the web of material, in the transport direction of the web of material, can be corrected, in particular, by a matching of the relative phase positions of the printing cylinders.
DE 199 60 649 A1 describes a device for correcting the lateral position of a web downstream of a dryer. A correction of the color register of the web is not provided by this device.
FIG. 1 of DE 86 10 958 U1 shows a curved lateral extension roller.
DE 83 04 988 U1 discloses a lateral edge control device for a screen printing machine. This device operates in connection with a pivotable roller.
U.S. Pat. No. 4,404,906 A shows a device for controlling the fan-out of a web by the use of a curved roller.
U.S. Pat. No. 6,550,384 B1 describes a device for correcting a width of a web of material. Adjustable deformation elements are looped by the web of material.
U.S. Pat. No. 5,553,542 A discloses a system for the regulation of the width of a web of material by the use of sensors and deformation units.
A rubber blanket with a varied profile for reducing the formation of creases is known from EP 0 659 585 A1.
SUMMARY OF THE INVENTION
The object of the present invention is directed to providing methods for accomplishing the reduction of register errors on a web of material, as the web is passing through a printing nip in a multi-color web-fed rotary printing press, and to corresponding devices.
In accordance with the present invention, this object is attained by establishing a deformation of a web in an area that is intermediate the lateral edges of the web, and areas which are adjacent to those lateral areas of the web, in a direction of travel of the web. The deformation is varied as a function of the register error in the web. A bendable roller, around which the web of material loops can have its curvature varied as a function of the register error. The bendable roller is situated at an inlet side of a printing group and is provided with at least one actuating element for setting its curvature.
Register errors, in the running direction of a web of material, are reduced by utilization of the present invention.
The advantages to be realized by the use of the present invention consist, in particular, in that it is possible, by the use of the present method, to reduce the second or higher orders of register errors, such as, for example a register error which occurs relative to the two sides of the web of material, and in particular, in the center of the web of material, which reduction in register errors is not possible with the known methods.
Moreover, it is possible, by the use of this invention, to control the register error over the entire width of the web as an S-line, so that on one side of the web, the register can be advanced in the direction of running, that register can remain in the zero position in the web center, such as, for example, at a seating location, and can be retarded opposite the direction of running on the other side of the press. This function can also be performed in the other direction transversely across the web.
The present invention can be configured to be considerably more simple, in comparison with the known methods. In particular, in comparison with the prior methods in which the module of elasticity of the web of material is affected, the method in accordance with the present invention can be controlled considerably more exactly. Register errors can accordingly be reduced more definitely and rapidly.
Advantageously, a zero order term of the register error is additionally reduced, in a known manner, by matching the relative phase position of the printing gap. A first order term of the register error, such as a register error which occurs on one side of the web of material, relative to the other side of the web of material, is reduced, in a generally known manner, by pivoting the roller, so that a shaft of the roller forms an angle with the printing gap.
It is possible, in this case, to detect the register error in the course of displacement, and the curvature of the roller can be adjusted while the web of material is running. Time is saved with this procedure, since the switch-off of the web of material and the later start-up of the web of material, such as is customary, for example, with width-adjusting rollers, which are curved when the press is stopped and which are pushed into a path of the web of material, is, as a rule, very time-consuming.
Customarily, the register error is detected on opposite edge areas of the imprinted web of material. This register error is compensated for by displacing, or by pivoting, the roller which is located upstream of the printing gap. In order to detect uncompensated terms of second or higher order of the register error, the register error should moreover also be measured in a center section of the web.
In a particularly preferred manner in accordance with the present invention, a marker is imprinted on the web of material in order to be able to detect the register error more easily.
A web-processing arrangement is suitable for executing the method of the present invention, which has a printing gap, through which a running web of material to be processed passes during the printing operation. A roller, which is arranged at the inlet side of the printing gap, can be curved. The web of material is at least partially looped around this roller during the operation of the device. At least one actuating member for use in setting a curvature of the bendable roller is provided. At least one sensor, for use in detecting a registration error on the web of material, is arranged at the outlet side of the gap or at the inlet of a following printing gap. An evaluation unit, that is connected with the sensor, is also connected with the actuating member for causing a change in the curvature of the bendable roller as a function of the detected register error and is used to reduce the register error by the use of this.
The bendable roller preferably is comprised of a shaft and a shell, and wherein the shell can be rotated around the shaft. In this case the shell can be supported, for example in the center of the shell by the shaft and on its ends, by a frame. The actuating member can be supported, on the one side, on the frame and can engage the shaft at the other side. It is also possible to displace the ends of the shell, relative to the shaft by the use of an actuating member, so that the center area of the shell remains approximately stationary and the ends of the shell are moved. In all cases the actuating member causes the bending of the shaft and of the shell, with respect to each other, so that, when viewed from the outside, the shell takes on a curved shape.
Advantageously the bendable roller can be seated, on two sides, in a frame, and wherein one end of the roller can be adjusted independently of the other. For example, this can be achieved wherein the bendable roller is seated, on at least one side, in an eccentric bearing positioned in the frame. Such seating of the bendable roller makes possible a simplified pivoting of the bendable roller, for reducing first order terms of the register errors, in such a way that a shaft of the roller forms an angle with the printing gap.
In a particularly preferred embodiment of the present invention, a deflection roller is provided, which deflection roller is arranged upstream of the bendable roller in respect to a running direction of the web of material, and which can be seated in different positions in the frame for use in adjusting the looping of the web of material around the bendable roller. This is of advantage, in particular, in connection with a bendable roller that is comprised of a shaft and of a rotatable shell, because such rollers are distinguished by an increased internal bearing friction. By setting a looping by the use of the deflection roller, and with this by accomplishing a force introduction into the bendable roller, it is possible to take care of this increased bearing friction. This moreover makes the device more flexible with regard to different paper types, for which a respectively ideal loop angle of the bendable roller can be set.
Preferably, the sensor is arranged in the center area of the web of material in order to detect register errors occurring there. In connection with this, at least one additional sensor, for use in detecting register errors, is provided in an edge area of the web of material in an especially preferred manner in accordance with the present invention.
As previously mentioned above, it is particularly preferred for the web-processing device to be a rotary rotogravure printing press.
BRIEF DESCRIPTION OF THE DRAWINGS
Preferred embodiments of the present invention are represented in the drawings and will be described in greater detail in what follows.
Shown are in:
FIG. 1 , a schematic side elevation view of a printing group of a rotary rotogravure printing press, in
FIG. 2 , a simplified cross sectional view through a first preferred embodiment of a bendable roller in accordance with the present invention, in
FIG. 3 , a schematic side view of a bearing of the bendable roller shown in FIG. 2 , in
FIG. 4 , a top plan view of a portion of the rotary rotogravure printing press of FIG. 1 , with a bendable roller which is pivoted obliquely in respect to the web of material, in
FIG. 5 , a side elevation view of a portion of the rotary rotogravure printing press from FIG. 1 with a slightly curved bendable roller, in
FIG. 6 , a side elevation view of a portion of the rotary rotogravure printing press from FIG. 1 with a greatly curved bendable roller, in
FIG. 7 , a simplified cross sectional view through a second preferred embodiment of a bendable roller in accordance with the present invention, in
FIG. 8 , depictions of the effects of different curvatures of the bendable roller on a web of material having image elements, in
FIG. 9 , depictions of the effects of different positions of various areas of the bendable roller on a web of material having image elements, and in
FIG. 10 , a schematic representation of devices for setting the register by the use of several deformation elements.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
A printing group of a rotary rotogravure printing press is shown schematically, in a side elevation view in FIG. 1 . In this printing group, a generally known forme cylinder 01 , as well as a generally known counter-pressure cylinder 02 , are seated in a frame, which is not specifically represented, and have been placed against each other in such a way that they form a printing gap 03 . A running paper web 04 is conducted through the printing gap 03 as the web 04 of material. Arrows indicate the running direction of the paper web 04 , as well as the directions of rotation of the forme cylinder 01 and of the cooperating counter-pressure cylinder 02 . A bendable roller 06 , such as, for example, a web guidance roller, and which roller 06 is not transferring ink, is arranged on the inlet side of the printing group ahead of the printing gap 03 , which roller 06 is also referred to as a deformable roller 06 . The paper web 04 loops, at least partially, around the roller 06 at a loop angle α, as seen in FIGS. 5 and 6 . A deflection roller 07 is seated in the frame upstream, with respect to the running direction of the paper web 04 , of the deformable or bendable roller 06 . The deflection roller 07 can be displaced into different positions in the frame, which displacement is indicated by a two-headed arrow that is shown in dashed lines in FIG. 1 . The looping of the web 04 around the roller 06 changes, as a function of the position of the deflection roller 07 . The deformable roller 06 comprises a shaft 08 seated in the frame, as well as a shell 09 which is seated so it is rotatable around the shaft 08 , as may be seen in FIG. 2 . In the embodiment of the roller 06 shown in FIG. 2 , an actuating member 11 , which is connected with an evaluation unit 12 and which is controlled by it, acts on each end section of the shaft 08 . It is also possible to have an actuating member 11 act on each end section of the shell 09 . The actuating members 11 can be operated electrically, pneumatically or hydraulically, for example. It is also possible to provide only one actuating member 11 , which may be located on only one side of the roller 06 . The evaluating unit 12 can be a control circuit or a micro-computer. Furthermore, a plurality of sensors 13 , 23 , as depicted in FIG. 1 , are connected with the evaluation unit 12 , which sensors 13 , 23 are arranged on the outlet side of the printing gap 03 and are oriented toward both edges, as shown by sensors 23 , FIG. 4 , as well as toward a center section, as shown by sensor 13 , of the paper web 04 .
The bendable or deformable roller 06 from FIG. 1 , which is seated in the frame 19 , as shown in FIG. 2 , is shown in longitudinal cross-section in FIG. 2 , while FIG. 3 represents the seating of the roller 06 in the frame 19 from a lateral point of view. As can be seen in FIG. 2 , the roller shell 09 is a hollow-cylindrical shell 09 , which is rotatable around a shaft 08 . The shell 09 is supported in its center area by one or by several bearings 17 , such as, for example, rolling bearings 17 , which have been inserted between it and the shaft 08 . The shaft 08 comprises two opposite end sections 14 , which are extended through the shell 09 . The shell 19 is rotatably held at both ends by the use of bearings 16 , such as, for example, rolling bearings 16 , in respective eccentric bushings or bearings 22 . Both eccentric bushings 22 can be rotated or pivoted by the evaluation unit 12 with the aid of a rotary actuator, which is not specifically represented. On one of its ends, each actuating member 11 acts on one of the end sections 14 , and on the other of its ends, each activating member engages the frame 19 via the respective eccentric bearing 22 .
During the operation of the rotary rotogravure printing press, the paper web 04 passes through the printing group along the path indicated in FIG. 1 . To overcome interior bearing friction of the roller 06 , as a result of the rotation of the shell 09 around the shaft 08 , the deflection roller 07 is seated on the frame 19 in such a position that the looping of the bendable or deformable roller 06 by the paper web 04 permits a sufficient force to flow into the roller 06 for overcoming the bearing friction. The paper web 04 is imprinted by the forme cylinder 01 in the course of its passing through the printing gap 03 . In the printing process, additional markings, such as so-called miniature point markers or register markers, are imprinted on the paper web 04 . Image elements of the actual printed image can also be used in place of these additional register markers. Register markers are understood to include additional register markers, as well as existing image elements of the actual printed image, such as, for example, portions of the individual color separation of the printed image. These register marks and/or image elements are detected by the sensors 13 , 23 . It is also possible for one sensor 13 , 23 to detect several register markers or several image elements. An occurring register error can be detected particularly easily and can be measured by the sensors 13 , 23 by the use of these register markers. The results of this detection by sensors 13 , 23 is passed on to the evaluation unit 12 from the sensors 13 , 23 . Depending on the size of the register error, the evaluation unit 12 will then issue an actuating signal to the actuating members 11 , as well as to the rotary actuators of the eccentric bearings 22 .
FIG. 4 represents a top plan view on the counter-pressure cylinder 02 and the roller 06 , with there being depicted a pivoting or a shifting, at a differently large degree, at the two ends of the roller 06 which are seated in the frame 19 . FIG. 4 also shows the paper web 04 , which is guided through the printing gap 03 , that is hidden by the counter-pressure cylinder 02 , and which is therefore shown in dashed lines and loops around the roller 06 from below in the perspective view represented. On the outlet side of the hidden printing gap 03 , a sensor 13 is oriented toward a center area of the paper web 04 in order to detect a register error occurring in this area. Moreover, further sensors 23 are arranged in the edge areas of the paper web 04 . All of these sensors 13 , 23 are connected with the evaluation unit 12 , which is not represented in FIG. 4 but which is shown in FIG. 1 .
If the actuating signals, which are transmitted to the two rotary actuators of the eccentric bushings 22 at the ends of shaft 08 are the same, the result is an initial pivoting at the two end sections 14 of the shaft of roller 06 by identical amounts, wherein both eccentric bushings or bearings 22 are pivoted by the same amount in the same direction in order to reduce a zero order term of the register error, as depicted in FIG. 9 . Differences in the actuating signals transmitted to the two rotary actuators for the eccentrics 22 result in pivoting of different amounts and directions at the two end sections 14 of the roller 06 , as represented in FIG. 4 , so that a shaft 21 or axis of rotation of the roller 06 and the printing gap 03 form an angle and make possible a compensation of the first order register error, which first order register error is mainly detected in the edge areas of the paper web 04 by the sensors 23 , as depicted in FIG. 9 . The roller 06 is thus skewed with respect to the printing gap 03 .
The second order terms of the register error are detected, in particular, by the sensor 13 and are reduced by accomplishing a bending of the roller 06 . To bend the roller 06 , the actuating members 11 press on the extended end sections 14 of the shaft 08 with a force, and in the process exert a force on the shaft 08 . The force exerted on shaft 08 is transmitted, via the rolling bearings 17 , to the shell 09 , which is bent as a result. The rolling bearings 17 assure that the shell 09 remains easily rotatable in spite of the considerable pressure and deformation forces exerted by the actuating members 11 . Bearings 17 are preferably configured as cylinder rolling bearings 17 in order to prevent the tilting of the shell 09 at the shaft 08 , which tilting could reduce the rotatability. As a result of the bending of the roller 06 , points which are located in a center area of the paper web 04 have to travel longer paths from the roller 06 to the printing gap 03 than do points which are located in the edge areas of the paper web 04 . This is made clear in FIGS. 5 and 6 .
As seen in FIGS. 5 and 6 the printing gap 03 , which is formed by the forme cylinder 01 and the counter-pressure cylinder 02 , the roller 06 and the paper web 04 , which paper web 04 is conducted through the printing gap 03 and which is looped around the roller 06 , are represented for different curvatures or bending of the roller 06 . The bendable roller 06 is arranged at a distance “a” from the printing gap 03 . The roller 06 is shown less bent in FIG. 5 , while in FIG. 6 it is depicted as being bent more strongly or substantially. To illustrate the situation clearly, the curvature of the roller 06 is greatly exaggerated in the drawings. In FIG. 5 a distance between the highest or most deformed point and the lowest or least deformed point of the barrel of the roller 06 is identified by “h”. Thus, the value “h” represents a measure of the curvature “h” of the roller 06 .
The direction of the curvature preferably extends close to, such as, for example +/−25°, and in particular +/−10° the direction of the bisecting line of the angle α wherein α is at least 45°, better yet is at least 90°, but preferably is between 95° and 115°.
Because of the curvature of the roller 06 , the paper web 04 is bulged out, in the direction toward the center of the web 04 , by the roller 06 . In FIG. 5 a path length “I” from the roller 06 to the printing gap 03 results from this bulging out or deflection for center points of the paper web 04 . This path length “I” is greater than the distance “a” from the roller 06 to the printing gap 03 which distance “a” must be traveled by points of the paper web 04 which are located at the edge of web 04 . The closer a point is to the center of the paper web 04 , the later it therefore arrives at the printing gap 03 .
If, as represented in FIG. 6 , the roller 06 is bent more, the curvature “h” is increased to “h′”. For center points on the paper web 04 , the path length “I” is also increased to the path length “I′”. With the increased curvature “h′” of the roller 06 , the center points therefore arrive even later in the printing gap 03 than do the points in the edge area of the paper web 04 . By adjusting the curvature “h”, “h′” of the roller 06 in this way, it is possible to determine how much later center points on the paper web 04 will arrive in the printing gap 03 , in comparison with points that are located in the edge area of the paper web 04 . Alternatively, in the running direction of the web 04 of material, the outermost points arrive at the printing gap 03 earlier than do the center points. This allows for the definite reduction of second or higher orders of terms of the register error.
In the same way, it is possible to set a displacement “h”/“h′” of the drive side, in the printing press center at a displacement 0 , and, on the operating side of the press, a displacement “h”/“h′” in the opposite direction. In this way, the printed line can be configured as an S-line over the width of the printing press.
An alternative embodiment of the bendable or deformable roller 06 is represented in FIG. 7 . This roller 06 also comprises a hollow shaft 08 and an elastic shell 09 , which shell 09 can be rotated around this shaft 08 . However, in this alternative embodiment, actuating members 18 are arranged on the shaft 08 inside the roller 06 . The actuating members 18 include rolling bearings 17 , through which members 18 push against the shell 09 from the inside and bend it in this way. In this case the rolling bearings 17 assure that the shell 09 can roll off the actuating members 18 as free of friction as possible.
In a further embodiment of the roller 06 , which is represented in FIG. 7 , second actuating members 18 are provided on the shaft 08 and are located in an arrangement which is not depicted, diametrically with respect to the represented actuating members 18 . The actuating members 18 can be controlled either individually or in groups. It is thus possible, by the use of the group control of the actuating members 18 , to bend the roller 06 into a roughly S-shaped form. Third actuating members 18 can also be provided on the shaft 08 , in addition to, or alternately to the second actuating members 18 , which act in a direction perpendicular to the action line of the represented actuating members 18 , or in a direction which forms any arbitrary angle with the action line of the represented actuating members 18 . A roller 06 , which is embodied in such a way, can even be bent into any arbitrarily wound shape with respect to the longitudinal direction.
As is represented schematically in FIGS. 8 or 9 , several image elements have been imprinted on a web 04 of material. Preferably, several first image elements have been imprinted side-by-side in a first printing group, and corresponding second image elements have been printed, also side-by-side in a second printing group. The schematically represented bendable or deformable roller 06 , which, in particular, is a web guidance roller 06 , belongs to the second printing group. By bending the roller 06 , and in particular by bending roller 06 perpendicularly to the running direction of the web 04 of material, the image elements of the second printing group will be shifted opposite to, or in the running direction in relation to the image elements printed on the web 04 by the first printing group.
The position of the center image elements is changed in relation to the position of the two outer image elements as a function of bending of the roller 06 . In another example, which is not specifically represented, the web 04 of material has at least four groups of image elements, each of which group of image elements is imprinted by a respective printing group. A bendable roller 06 is assigned to at least each of the last three of the at least four printing groups. The evaluation of this group of image elements can take place by the use of at least one sensor 13 , 23 , which sensor evaluates at least one image element of the at least four printing groups. Actuating elements for bending at least three rollers are operated as a function of the signal(s) of a sensor 13 , 23 , as discussed previously.
It is also possible to employ a roller with individual roller barrel sections 26 , or with curved, such as, for example, with wheel-shaped, deformation elements 26 , which can be adjusted in relation to each other, as seen in FIG. 10 , in place of a continuous roller.
A contactless deformation of the web 04 of material is also possible, in particular by the use of compressed air, such as, for example, by adjusting the amount of air and/or the air pressure, or by changing the spacing of an air outlet opening.
The deformation of the web 04 of material at the deformation location, by the use of the bendable roller 06 or the deformation elements 26 takes place perpendicular to the running level of the web 04 of materials.
The roller 06 can be deformed in a direction which lies within a range of +/−25°, and in particular of +/−10°, in relation to a bisecting line of the wrap angle α.
Preferably, the deformation of the web 04 of material by operation of the roller 06 , or by use of the deformation elements 26 , does not take place in any printing gap 03 .
In addition to setting the register in the running direction of the web 04 of material, an adjustment of the registration transversely to the running direction, in response to for example, a temperature change, and in particular an increase in the temperature which causes shrinkage in a dryer between two printing gaps, and/or the introduction of moisture, such as, for example, saturated water vapor, for widening the web can take place. Preferably, a regulation or a setting of the register takes place first in the running direction, and then a regulation setting of the register takes place transversely to the running direction of the web.
While preferred embodiments of methods for reducing register errors on a web of material moving through the printing nip of a multi-color web fed rotary printing press and corresponding devices have been set forth fully and completely hereinabove, it will be apparent to one of skill in the art that various changes, for example, in the web of material to be printed, the structure of the forme cylinder and counter-pressure cylinder in each printing group, 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 appended claims. | The invention relates to a method for reducing register errors on a web of material ( 04 ) moving through the printing nip of a multicolor web-fed rotary press, comprising the following steps: providing a portion between an area of the web of material ( 04 ) located between the two lateral edges of the web of material ( 04 ) and areas in the vicinity of the lateral edges of the web of material with a deformation relative each other in a direction perpendicular to the plane of rotation of the web of material ( 04 ) subject to a register error occurring in the direction of rotation of the web of material ( 04 ). | 1 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims the benefit of U.S. Provisional Patent Application No. 60/498,397, filed on Aug. 27, 2003, which is hereby incorporated by reference in its entirety for all purposes.
BACKGROUND
[0002] Wind driven toys are quite popular. For instance, some wind driven toys may include kites, toy sailboats, and pinwheels, among others. Toys for use in the outdoors are very popular and are probably increasing in popularity with the recent increase of people enjoying outdoor activity. Quite often, even the slightest breeze will bring out a number of kite fliers flying everything from the simplest kite to very elaborate stunt kites. Additionally, pinwheels, whirligigs, and other such wind driven toys can be amusing to watch on breezy days.
[0003] Although these wind-actuated toys are well known and widely used, they may suffer from a serious drawback. Some wind driven toys are static, in that the user of a kite or toy sailboat, for example, uses these devices while remaining substantially stationary. Such devices are incompatible with the desire to enjoy a breezy day while exercising. This drawback of these toys is especially noticeable given the emphasis on activity and exercise prevalent in society today. It is quite well known that a sedentary lifestyle and maintaining a healthy body may be mutually exclusive ideas. Therefore, it may be advantageous to have an action toy that would allow people to have fun on a windy day as kites and other such devices allow, while also providing the opportunity for enjoying an aerobic workout. Such an action toy could also encourage people to abandon indoor, sedentary habits and activities, such as video games, watching television, surfing the Internet, and the like, among others.
[0004] A drawback of many other popular action toys may be that they require a power source of some sort, whether batteries or otherwise. Advantageously, with the increased emphasis on environmental friendliness in all aspects of peoples' lives, a decrease in power consumption and/or disposable battery consumption would be enjoyed by all. Therefore, it would be desirable to have an action toy not requiring an outside, polluting power source.
[0005] Furthermore, flying discs and the like may be limited in the distance they travel by their design and by the amount of force that can be applied by a user. Therefore, it would be advantageous to have a toy that would travel relative long distances with little or no force imparted to it by a user. Yet further, it would be advantageous to have an inexpensive toy that can be easily replaced if broken.
SUMMARY
[0006] Provided is a wind propelled rolling toy that may be formed in a relatively small, single sheet of material, and that may be easily assembled and used by a user. The device may include a body portion coupled to a sail portion wherein the sail portion is configured to utilize wind as a propulsion source, along with a self-adjusting device or configuration that may continuously optimize the sail angle relative to the direction of wind and the direction of travel of the device. Other exemplary embodiments may include a standardized frame portion that mat be configured to accommodate a wide variety of portions and accessories. Furthermore the system may be capable of many configurations and themes.
BRIEF DESCRIPTION OF THE DRAWINGS
[0007] FIG. 1 is an exemplary embodiment of a vehicle system according to the present invention.
[0008] FIG. 2 is an exploded, elevational view of an exemplary embodiment of a vehicle system.
[0009] FIG. 3 is an exploded, elevational view of an exemplary embodiment of a vehicle system.
[0010] FIGS. 4 a - d are perspective views of exemplary embodiments of axle systems.
[0011] FIGS. 5 a - d are perspective views of exemplary embodiments of axle systems.
[0012] FIG. 6 is a perspective view from the underside of an exemplary embodiment of a vehicle system.
[0013] FIG. 7 is an exploded, perspective view of a vehicle system according to an exemplary embodiment.
DETAILED DESCRIPTION
[0014] The detailed description set forth below in connection with the appended drawings is intended as a description of exemplary embodiments and is not intended to represent the only forms in which the embodiments may be constructed and/or utilized. The description also sets forth the functions and the sequence of steps for constructing and operating the exemplary embodiments in connection with the illustrated embodiments. However, it is to be understood that the same or equivalent functions and sequences may be accomplished by different embodiments that are also intended to be encompassed within the spirit and scope of this disclosure.
[0015] Exemplary embodiments disclosed herein may include a simple, wind-driven, generally non-mechanized action toy vehicle that does not require batteries or other power sources. The methods and systems disclosed herein may also provide an amusing play action wherein the user can actively walk or run along with the system and enjoy active exercise. The user and observers may enjoy its rolling travel and animated sail action, such as a rider assuming various reactive postures, and graphic effects. The play action and value may also be enhanced by the graphics and configuration of the system in the forms of a skateboarder, roller skater, racing vehicle, surfer, and the like. Furthermore, the manufacturing and packaging methods may reduce costs sufficiently to allow the system to be offered for a relatively low price, or given away as a promotional item.
[0016] A vehicle system according to an exemplary embodiment is shown in FIG. 1 , generally at 10 . System 10 may include a sheet 12 as well as coupling components 14 (not shown in this figure). Sheet 12 may include removable portions 20 . Removable portions 20 may include a first shape 22 , a second shape 26 , a third shape 30 , and a fourth shape 32 . In this embodiment, the first shape 22 may be in the form of a sail, while second shape 26 may be in the shape of a body portion. Third shape 30 may be in the form of a wheel in this embodiment, and fourth shape 32 may be in the form of a fin or tail in this embodiment. As shown, shapes may be removable from sheet 12 and may include graphics and/or other configurations such that they may be easily assembled into a three dimensional vehicle.
[0017] In this embodiment, components 14 (not shown) may include an axle, a sail coupling adapter, as well as other adapters and piece parts that may facilitate coupling the shapes together to form a three dimensional vehicle. Alternatively an axle may be configured with the body portion, as desired. Sheet 12 may be made from a material such as expanded polystyrene, polyethylene, relatively thin cardboard, nerf-type foam material, or other generally lightweight, durable, and inexpensive material, but may be made from other materials, as desired. The shapes may be die cut or “kiss-cut” where the resultant sheet may be packaged and sold intact. Furthermore, they may be die cut to easily be removed from sheet 12 by a user, such as a child. However, some parts may be removed from the sheet during manufacturing, and placed within the package so as not to require them to be punched out by the user prior to assembly.
[0018] Wheel 30 may include a bushing 34 which may facilitate the wheels rotating about an axle more easily to allow the system 10 to roll with little force acting upon it, such as a slight breeze, among others. Furthermore the bushings 34 may spread the dynamic load of the system to allow the use of low mass material for other portions of the system. With this configuration a vehicle system may be produced inexpensively and may be easily put together by a child and used as a toy. This type of system may be very inexpensive to manufacture and distribute, such that the price may be relatively low, which may make user's more likely to purchase multiple systems, or advertisers to give them away.
[0019] Body portion 26 may include an orifice 36 and a slot 38 . Orifice 36 may be configured to allow a sail coupling adapter to fit therethrough. Furthermore, a bushing may be included in orifice 36 to facilitate the movement of components, as well as add to the durability and longevity of the system. Furthermore the bushings may spread the dynamic load of the system to allow the use of low mass material for other portions of the system. This bushing may have the same configuration as bushing 34 to further reduce manufacturing costs.
[0020] Slot 38 may be configured to allow a portion of the coupler acting as a stop, to rotate within the angular limits of slot 38 , such that the sail may be limited in travel, such that it may move with the wind to utilize wind forces to move the entire system. Furthermore this configuration may provide a self-adjusting sail configuration that may adjust to the wind to allow the system to travel a longer distance.
[0021] It will be appreciated that the sail may have many orientations with respect to the body portion, i.e. facing generally parallel, perpendicular, etc. with respect to the body portion. Furthermore, the sail may be located in many positions adjacent the body. More than one sail may be utilized with one body portion.
[0022] System 10 may also further include other accessories, which may couple to various portions of the vehicle and/or system to enhance the appearance and may also enhance the play value of the system. These other accessories may also include noisemakers, lighting effects, stickers, graphics, and the like, which may be included in the system package, but not necessarily formed in sheet 12 .
[0023] The systems disclosed herein are designed to depict a broad range of themes. It will be appreciated that various components of the system may be utilized with other systems, making the system highly configurable. The use of light-weight material may also provide safety and crash resistance, relatively fast acceleration, and low overall cost of construction and shipping, among others.
[0024] FIG. 2 may show another exemplary embodiment of a system, generally at 40 . System 40 may include a body portion 42 as well as one or more axle portions 44 coupled thereto. Axle portions 44 may be coupled to body portion 42 in many different ways including gluing, adhesives, friction fit, interference fit, or other configurations and methods of coupling axle 44 to body portion 42 , as desired.
[0025] Axles 44 may be telescoping or of varying widths to receive many different types, widths, etc. of wheels and bodies. This may include wider wheels, which may give the system a customized appearance. Furthermore a wider or longer axle configuration may aid the performance of the system in higher wind conditions.
[0026] System 40 may also include a sail portion 46 which may be configured to rotatably couple to body portion 42 , generally at the top of body portion 42 , via sail or mast stop adapter 50 and sail bushing 52 . Sail bushing 52 may be configured to fit through orifice 54 and couple to retainer 56 to allow adapter 50 and sail portion 46 to be rotatably coupled to body portion 42 . Adapter 50 may include a portion that may extend through slot 58 within body portion 42 such that the sail 46 and adapter 50 may be limited in travel such that once the vehicle is moving, the sail may automatically adjust to utilize the forces of a breeze or wind to continue moving. Furthermore, adaptor 50 may couple to sail 46 and to body portion 42 to allow for continuous, self-adjusting, optimization of the sail position relative to the wind direction and vehicle travel direction. It will be appreciated that sail portions, and/or other portions of the various embodiments may be expandable and generally 3-dimensional.
[0027] System 40 may further include one or more wheel portions 48 which may rotatably couple to axle 44 near the ends of axle 44 , and may be secured to axle 44 via hub 49 . Furthermore, wheel 48 may include a bushing 47 which may be made of a hard plastic or other material such that it would more freely rotate about axle 44 . As discussed in the previous embodiment, the coupling components/accessories included with the system may include the adapter 50 , sail bushing 52 , connector 56 and hub 49 , among others. In this manner, small piece parts may be included in the system separately from the sheet and/or preassembled onto their respective positions on the portions of the sheet. The user may assemble the preassembled subassemblies before use. The retainers, hubs, etc. may be precoupled to the system and the user may remove them and recouple them after assembling the system.
[0028] Wheels in the various systems may be transparent or semi-transparent, which may make the system appear as if it is floating. Furthermore the wheels may be located under the body portion, such that the wheel may not be easily seen.
[0029] In this embodiment body portion 42 may come with axles 44 already attached or coupled thereto, however there may be an adhesive strip or other configuration for coupling axle 44 to body portion 42 .
[0030] In an exemplary embodiment, sail bushing 52 may be made from a plastic material and may be pre-affixed to the sail and/or body 42 prior to shipment, as desired. Adaptor 50 may be configured to extend through, and ride on, sail bushing 52 in the body such that the sail may be capable of lateral movement to better translate wind forces onto vehicle motion, depending upon the direction of the wind and the direction of the travel of the vehicle.
[0031] With this configuration, a relatively small, lightweight, inexpensive, easy to assemble child's toy may be made such that a user, such as a child, will be able to construct and use the vehicle relatively easily. The relatively small package, as a wrapped/backed single sheet or as a box or such containing other parts, may make it very easy to ship numerous amounts of the article of the system such that it will not take up a lot of space in packaging, shipping, storage, and display, thus making the system more attractive to retailers and users. The inexpensive nature of the system may make the system attractive to buyers as it may be easily replaced if broken, or many systems with the same or different graphics and designs may be purchased for or by a child. Therefore, these systems may configured and manufactured in a variety of sizes, including sized and used as trading cards, and the like. Furthermore, many themes may be utilized that may appeal to potential purchasers as a trading-card type product.
[0032] The system may be configured to allow the vehicle system to change directions, and/or to travel in one direction when the direction and velocity of the wind changes. Other accessories may be utilized, such as ballasts or other accessories, to enhance the characteristics of the vehicle and to enhance play value of the overall system.
[0033] In an exemplary embodiment, the slot 58 may be configured to receive the adaptor 50 . It may be located along the centerline of the length of the body, and may be configured in a location where it can best convert the wind force from the sail into movement of the vehicle, without causing the vehicle to become unstable or to overturn. In an exemplary embodiment, the slot 58 may function to contain and permit free rotational movement of the adaptor 50 within the slot limits.
[0034] Further aspects of the exemplary embodiments may include that the overall geometry and continuously self-adjusting sail configuration may automatically enable the vehicle to track the wind forces to allow the vehicle to move about. Another aspect of the exemplary embodiments may be that the resultant low weight and low mass design may limit damage to the system in the event of a crash. This aspect may also allow rapid animated acceleration and desirable speeds in response to mild wind forces and wind changes.
[0035] FIG. 3 shows another exemplary embodiment of a toy vehicle system, generally at 60 . System 60 may include a body portion 62 as well as a frame 64 , which may be configured to removably couple to body portion 62 via securing structures 86 . It will be appreciated that although a generally flat body portion 62 is shown, many different three-dimensional configurations may be utilized with this embodiment for many different types, styles, and configurations of vehicles.
[0036] System 60 may further include a wheel adapter 66 which may be configured to couple to wheel receivers 82 . With this configuration, the system may be highly configurable to allow a user to place wheel portions 68 and wheel adapter 66 in many different positions with respect to the frame 64 , as well as having multiple wheels on the vehicle, if desired. Furthermore, although five wheel receivers 82 are shown on each side of frame 64 , it will be appreciated that many other numbers and configurations may be utilized without straying from the concepts disclosed herein.
[0037] This exemplary embodiment may include a dimensionally standardized chassis and universal configuration designed to accommodate a wide variety of vehicle configurations by allowing for alternate positions for axles, sail pivot points, plug in accessories, such as ballast, etc.
[0038] System 60 may further include wheels 68 which may be configured to rotatably couple to wheel adapter 66 . This configuration will allow the system to move along a support surface with a reduced amount of force, such as, but not limited to, a breeze. System 60 may further include a coupler 70 which may be configured to removably couple wheel adapter 66 to frame 64 .
[0039] System 60 may yet further include a sail portion 72 as well as a sail support 74 and coupling configuration 76 and mating structure 78 . With this configuration, sail support 74 may extend through coupling configuration 76 . Coupling configuration 76 may be configured to extend into an orifice 79 to rotatably couple sail portion 72 to frame 64 .
[0040] System 60 may further include a sail stop 80 which may couple to coupling configuration 76 and/or sail support 74 , may be configured to limit the rotation of sail portion 72 with respect to frame 64 . As shown, there is more than one orifice included in frame 64 such that the sail may be coupled to the system at various points with respect to frame 64 . Furthermore, more than one sail may be coupled to the system, as desired.
[0041] It will be appreciated that although an exemplary embodiment for frame 64 is shown, many other configurations for a frame may be utilized. Other configurations may include, but are not limited to, a generally I-shaped configuration, a box-like configuration, a “criss-cross”-type configuration, and/or a configuration with a generally central backbone and multiple cross beams, and the like. These alternate configurations may be utilized with none, some, or all of the portions disclosed herein, as desired, without straying from the concepts disclosed herein.
[0042] Axles may be made from the expanded polystyrene, a generally hard plastic, or polyethylene material, and/or other materials and combinations thereof, as desired. In other exemplary embodiments the axles may be made of another material such as, but not limited to, wooden dowels, hard plastic, solid or tubular metal, and/or combinations thereof, and the like, and may be included in the configuration of the body portion, or shipped separately from the sheet, but in the same package, as desired.
[0043] It will be appreciated with this highly configurable system, many different configurations may be utilized which may make it more attractive to a purchaser, such as a child. Furthermore, the portions may be interchangeable such that many different portions may be used with different systems to make the system even more configurable. Furthermore, with the removable coupling configuration of body portion 62 with respect to frame 64 many different styles of body portions may be utilized with this highly configurable system.
[0044] FIG. 4 a shows a wheel securing configuration and/or axle means according to an exemplary embodiment, generally at 90 a . Configuration 90 a may include an axle 92 and a body 94 such that axle 92 may be coupled to body 94 as described above with an adhesive strip, as well as other securing configurations and methods, and also may come from the factory already secured to body portion 94 .
[0045] FIG. 4 b shows a wheel securing configuration and/or axle means according to another exemplary embodiment generally at 90 b . Configuration 90 b includes an axle 92 and a body 94 as in the embodiment in FIG. 4 a , as well as a coupling configuration 96 which may be configured to couple axle 92 to body 94 . This configuration may also come pre-made from the factory, and/or may be easily accomplished by a user, if desired.
[0046] FIG. 4 c shows a wheel securing configuration and/or axle means of another exemplary embodiment, generally at 90 c . Configuration 90 c includes a body portion 94 and an axle 98 coupled thereto. In this configuration, axle 98 has a generally zigzag configuration which may improve the stability of the system as well as add to the aesthetics, among other considerations. Axle 98 may again be coupled to body 94 via an adhesive or other configurations or methods, or may come from the factory to the user already coupled.
[0047] FIG. 4 d shows another wheel securing configuration and/or axle means according to another exemplary embodiment, generally at 90 d . Configuration 90 d may include a body portion 94 as well as one or more axles 100 . With this configuration axles 100 may not extend entirely across body portion 94 which may save money and/or reduce packaging size among other considerations. Furthermore, again axles 100 may be couplable to body portion 94 in various locations, by the user, or may come from the factory with this configuration. Body portion 94 is typically made of a styrofoam-type or polystyrene material, but may be made from balsa wood, woods, plastics, and/or combinations thereof, without straying from the concepts disclosed herein. Furthermore, in FIGS. 4 a - 4 d , axle portions may be made of a metal, plastic, wood, polymers, and/or combinations thereof, as desired, without straying from the concepts disclosed herein.
[0048] FIG. 5 a shows a wheel coupling configuration and/or axle means according to an exemplary embodiment, generally at 110 a . Configuration 110 a may include an axle portion 112 as well as a body portion 114 . In this configuration, axle may be made of a wood material and may be coupled to body portion 114 via an adhesive, or other configuration or method. Furthermore the axle 112 may be coupled to body portion 114 via an adhesive or other configuration and may be configured to be coupled by a user, or may come already assembled. With this configuration axle 112 may be made of wood and may be very inexpensive. Furthermore, the system may be highly configurable and inexpensive.
[0049] FIG. 5 b shows another exemplary embodiment of a wheel coupling and/or axle means configuration, generally at 110 b . Configuration 110 b may include an axle 112 and a body portion 114 as well as an adapter 116 . Adapter 116 may couple to body portion 114 as well as axle portion 112 . This may add stability to the system and may also add rigidity to the system. Furthermore, this may allow for a alternate configuration as to the spacing of wheels with respect to body portion 114 .
[0050] FIG. 5 c shows another exemplary embodiment of a wheel coupling and/or axle means configuration, generally at 110 c . Configuration 110 c may include a body portion 114 as well as wheel couplers 118 coupled thereto. With this configuration, wheel couplers 118 may be small injection molded parts, which may be included with the system easily and inexpensively. Again, wheel coupler 118 may come from the factory already fixed to body portion 114 , or may be fixed by the user, or may be removably fixed, as desired.
[0051] FIG. 5 d shows a wheel coupling configuration and/or axle means according to another exemplary embodiment, generally at 10 d . Configuration 110 d may include a body portion 114 as well as adjustable wheel couplers 120 . As shown, adjustable wheel couplers 120 may be moveable and selectively postionable with respect to body portion 114 . This may make the system highly configurable and may make it more attractive to a potential purchaser such as a child. This again makes the system very highly configurable and highly adjustable, as desired.
[0052] In FIGS. 5 a and 5 b axle 112 may be made of wood, plastic, or other material and/or combinations thereof. In FIGS. 5 c and 5 d , wheel coupler 118 and adjustable wheel coupler 120 may be made of plastic, metal, wood, polymers and/or combinations thereof, as desired.
[0053] FIG. 6 shows a perspective view from the underside of a system 130 according to an exemplary embodiment of a wind powered vehicle. System 130 may include a frame 132 as well as axle portions 136 . Axle portions 136 may couple to frame 132 via a friction and/or interference fit, as well as other methods and configurations, as desired. Frame 132 may include orifices 134 which may allow other portions of the system to couple thereto.
[0054] Axle portions 136 may include body coupling structures 138 which may be configured to reversibly couple to a body portion (not shown). It will be appreciated that although body coupling structures are shown as being able to couple to a body portion via friction or interference fit, other configurations may be utilized, without straying from the concepts disclosed herein.
[0055] Axle portion 136 may further include wheel receivers 140 which may be configured to rotationally couple to wheel portions (not shown). It will be appreciated that since axle portions 136 may couple to frame portion 132 in many different configurations such that many axle portions 136 may couple to a body portion 132 as well as coupling to the body portion in many different positions, as desired. Axle portion 136 may also include tabs 142 which may facilitate coupling and decoupling of the body portions, wheel portions, and other portions of the system, as desired. Furthermore, tabs 142 may facilitate the telescoping action of axle portions 136 to accommodate for the use of different body portions and styles, as wall as different wheel configurations. This configuration may also facilitate altering the configuration of the system to adjust for different wind conditions.
[0056] System 130 may further include a sail adapter 152 which may be configured to couple and decouple to a sail in many different positions. Sail adapter 152 may extend into and/or otherwise couple to bolt 148 which may extend through orifice 134 of body portion 132 to couple to nut 150 . Although a nut and bolt configuration has been shown, it will be appreciated that many other configurations and methods may be utilized to couple these items together, as desired.
[0057] System 130 may further include limitors 146 and stop 144 which may also couple to bolt 148 . In this manner, the positions of limitors 146 may be varied to vary the travel of the sail as limited by stop 144 . Stop 144 may also be threaded and screw onto bolt 148 however, other coupling methods and configurations may be utilized as desired.
[0058] System 130 may also include a sail receiver 154 which may be configured to receive the coupling configuration as described above. This may allow different positions for a sail to be coupled to the system as well as more than one sail being coupled to the system, as desired. This may further enhance the configurability of the system and may make the system more attractive to potential purchasers. Although a generally I-shaped configuration is shown, it will be appreciated that other simply configurations may be utilized with straying from the inventive concepts herein. Furthermore sail receiver 154 may be coupled at the ends of frame 132 to extend the frame 132 and to allow sails to be coupled to the system at those extensions.
[0059] This exemplary embodiment may include a dimensionally standardized chassis and universal configuration designed to accommodate a wide variety of vehicle configurations by allowing for alternate positions for axles, sail pivot points, plug in accessories, such as ballast, etc.
[0060] With this somewhat simple design, the system may be inexpensive, have very few parts, may be highly configurable, and may portions of the system may be utilized with other systems, as desired. These inexpensive and highly configurable configurations may make it more likely for a child or parent to purchase one or more systems.
[0061] Wheels for the system may be of varying width and height and may be coupled to varying numbers of axles. Axles may be located through various parts of the system. One or more sails may be coupled to the system in different arrangements and may have different pivot locations located throughout the system. Furthermore, bodies may be included with the system that may have side skirts, wheel wells and/or body pans, as desired. Yet further, a variety of add-ons and accessories may be included and/or sold separately to further enhance the configurability of the overall system.
[0062] Ballast and other accessories may be utilized with the system to change the characteristics thereof. Furthermore with this frame configuration, many different body portions 132 may be utilized by adjusting the frame and axle portions (undercarriage and chassis) thereof. Furthermore the axle portions 136 and wheel portions 140 may be extendable and may be made in different lengths and specifications such that many, many different wheels, bodies, sails, etc. may be utilized with the various systems.
[0063] FIG. 7 shows an exemplary embodiment of a vehicle system, generally at 160 . System 160 may include a body portion 162 as well as a sail portion 164 . Body portion 162 as shown, may be three-dimensional and in this embodiment, shown as waves. Furthermore, sail portion 164 may include graphics such as a wind surfer and/or other graphics such that it may appear that a wind surfer is surfing through water as the vehicle moves along a surface.
[0064] System 160 may further include a sail adapter 166 which may be configured to couple to sail 164 and configured to extend through orifice 168 within body portion 162 . This configuration may rotatably couple sail 164 to body 162 . Sail adapter 166 may be configured to couple to sail stop 170 . Sail adapter 166 may also extend through limitor 172 as well as adjustable limitor 174 that may make the limiting of rotation of sail 164 with respect to body portion 162 variable. With this configuration, the travel of sail laterally may be limited by sail stop 170 and limitor 172 such that it may be adjusted for various conditions. This configuration may make the system more configurable for different wind and/or other force conditions.
[0065] System 160 may include an axle portion 176 which may be formed within and/or coupled to body portion 162 , or other configurations as shown in the previous figures, or other configurations, as desired. System 160 may further include a locking portion 180 which may be configured to couple axle portion 176 to body portion 162 .
[0066] In this embodiment axle portion 176 may be configured to be telescoping. This configuration may accommodate for the use of different body portions and styles, as wall as different wheel configurations. This configuration may also facilitate altering the configuration of the system to adjust for different wind conditions.
[0067] System 160 may further include a wheel portion 178 which may be configured to rotatably couple to axle portion 176 such that it would provide a configuration for the system to move on a support surface, utilizing very low forces such as a breeze, wind, and/or other forces, as desired.
[0068] As shown by the various embodiments of this invention, the system is very highly configurable which may appeal to many different users and/or buyers, including children and/or parents. Furthermore, the system may be made from very lightweight and inexpensive products making it inexpensive to manufacture and to sell and/or give away. Furthermore, the system may be configured to be easily assemblable by a user such that it may be assemblable by children.
[0069] Furthermore, as described by the exemplary embodiments, the system may include graphics and other accessories that may make it appealing to users, such as children. The systems may be formed relatively small such that they may be the size of trading cards to further make them attractive to children. In operation, the sail may move rapidly, in a self-adjusting manner. The additional movements of the sail and other accessories may cause the vehicle and/or other portions of the system to appear animated. Many different vehicles and toys may be configured and produced in this manner, with this configuration.
[0070] In exemplary embodiments disclosed herein, the vehicle may be designed to be very lightweight and low mass, being primarily made from low-density foam sheets, and yet they may be stable, self-adjusting, and may uniquely portray a wide variety of subjects, including, but not limited to, human, animal, or fanciful figures, and/or high-performance land and water vehicles, and the like. Moreover, the system may incorporate a relatively simple configuration to allow the sail to continuously adjust to the wind direction and forces for any particular downwind or crosswind path of vehicle travel. In exemplary embodiments, the configuration may take advantage of the switching, opposing wind directions to enhance the animated effect of rolling to and fro. Furthermore, this may be a learning toy such that a child or other user may learn about wind and other forces, sailing and vehicles. This may make the system more likely to be purchased by a parent for a child to facilitate the learning of the child.
[0071] In closing, it is to be understood that the exemplary embodiments described herein are illustrative of the principles of the present disclosure. Other modifications that may be employed are within the scope of this disclosure. Thus, by way of example, but not of limitation, alternative configurations may be utilized in accordance with the teachings herein. Accordingly, the drawing and description are illustrative and not meant to be a limitation thereof. | Provided may be a wind propelled rolling vehicle with a self-adjusting said that may be substantially formed in a relatively small, single sheet of material, or assembled onto a standard chassis. The exemplary embodiments may utilize bushings to spread dynamic loads so as to allow the use of very light structural material such as thin sheet foam thereby forming a safe, low-mass toy vehicle capable of achieving good acceleration and rolling speed relative to a given wind force, and configurable into many themes. | 0 |
STATEMENT OF GOVERNMENT INTEREST
[0001] The invention described herein may be manufactured and used by or for the Government of the United States of America for governmental purposes without the payment of any royalties thereon or therefore.
CROSS-REFERENCE TO RELATED PATENT APPLICATIONS
[0002] Not applicable.
BACKGROUND OF THE INVENTION
[0003] (1) Field of the Invention
[0004] The present invention relates to computer model of hydrodynamic flows and more particularly, relates to modeling partially cavitating flows over a supercavitating axisymmetric body.
[0005] (2) Description of the Prior Art
[0006] Modeling of boundary flows about objects subject to laminar and turbulent flows is well known in the art. High speed underwater vehicles, however, cause cavitation of the surrounding fluid. Cavitation reduces pressure in the fluid below its vapor pressure causing the fluid to vaporize, allowing the undersea vehicle to travel with lower friction when the vehicle is completely surrounded by the cavity.
[0007] Partial cavitation is an unsteady phenomenon that occurs when part of the supercavitating vehicle is traveling in the cavity. Specifically, this phenomenon occurs during launch of the vehicle. A steady, partial cavitation allows development of vehicle designs which take advantage of drag reduction through cavitation. It may also be possible to take advantage of drag reduction with partial cavitation by properly directing the re-entrant jet that forms in the cavity closure region. Partial cavitation often occurs during maneuvering of the supercavitating vehicle.
[0008] A slender body theory has been developed to solve axisymmetric supercavitating flows. Using the slender body method, sources are defined along the body-cavity axis and control points along the body-cavity surface. A nonlinear differential equation is formed by imposing dynamic boundary conditions on the cavity. A conical cavity closure is assumed in order to solve the developed nonlinear differential equation.
[0009] A non-linear boundary element method for determining a cavity shape has been developed. Source and dipole strengths along the body-cavity surface are determined using kinematic boundary conditions on the wetted body surface and dynamic boundary conditions on the assumed cavity shape. The kinematic boundary condition is then used to update the cavity shape. The process is then iterated to solve for the unknown cavity shape.
[0010] Two numerical hydrodynamics models have been developed by the Naval Undersea Warfare Center for axisymmetric super cavitating high speed bodies. These models are the slender body theory (SBT) model and the boundary element (BE) model. Both of these models have been proven to predict cavity shape and parameters with good accuracy.
[0011] These models, however, do not account for the transition case when the vehicle is subjected to only partial cavitation.
[0012] In the SBT model, total drag is predicted by adding the pressure drag obtained from the model solution and the viscous drag obtained by applying the Thwaites and Falkner-Skan approximations along the wetted portions of the cavitator. This method is extended to subsonic compressible flows using the compressible Green's function. In the BE model, sources and dipoles are defined on the body-cavity shape and are solved using Green's formula. This yields a Fredholm integral equation of the second kind which gives the supercavitating cavity shape.
[0013] Partial cavitation modeling has been done by Uhlman, J. S. (1987), The Surface Singularity Method Applied to Partially Cavitating Hydrofoils, Journal of Ship Research, Vol. 31, No. 2, pp. 107-24; Uhlman, J. S. (1989), The Surface Singularity or Boundary Integral Method Applied to Supercavitating Hydrofoils, Journal of Ship Research, Vol. 33, No. 1, pp. 16-20; Kinnas, S. A., and Fine, N. E. (1990), Non-Linear Analysis of the Flow Around Partially and Super-Cavitating Hydrofoils by a Potential Based Panel Method, Proceedings of the IABEM-90 Symposium, International Association for Boundary Element Methods, Rome, Italy, and Kinnas, S. A., and Fine, N. E. (1993), A Numerical Nonlinear Analysis of the Flow Around Two- and Three-Dimensional Partially Cavitating Hydrofoils, Journal of Fluid Mechanics, Vol. 254. However, these methods are explicitly adapted for hydrofoils, and the theories presented therein are not readily adapted to supercavitating vehicles.
SUMMARY OF THE INVENTION
[0014] One object of the present invention is a method for modeling partial cavitation.
[0015] Another object is that such method model partial cavitation about an axisymmetric vehicle.
[0016] Accordingly, the present invention provides a method for calculating cavity shape for partial cavities about an axisymmetric body having a cavitator located at the foremost end. The method includes receiving system parameter data including geometric data describing the axisymmetric body, a cavity length, and a convergence tolerance. Boundary element panels are distributed along the body-cavity surface and matrices are initialized for each boundary element panel using the unit dipole, unit source functions and known boundary values. Disturbance potential matrices are formulated for each boundary element panel using disturbance potentials, normal derivatives of disturbance potentials, and no net flux boundary conditions. The initialized matrices and the formulated matrices are solved for each boundary panel to obtain unknown disturbance potentials along the wetted body-cavity surfaces, and normal derivatives of disturbance potentials along the cavity surface. The cavity position is then updated by moving each panel to satisfy the kinematic boundary condition, no flux across the cavity. The method then tests for convergence against a tolerance, and steps are iterated until convergence is achieved. The method then provides parameters of interest and the location of the cavity as output. Another aspect of this invention allows the calculation of cavity shape and cavity length for an input cavitation number. This is accomplished by an outer loop adjusting cavity length until the model converges to the input cavitation number.
BRIEF DESCRIPTION OF THE DRAWINGS
[0017] These and other features and advantages of the present invention will be better understood in view of the following description of the invention taken together with the drawings wherein:
[0018] [0018]FIG. 1 is a diagram of a partially cavitating axisymmetric body related to the method of the current invention; and
[0019] [0019]FIG. 2 is a flow chart of the method of the current invention; and
[0020] [0020]FIG. 3 is a flow chart of another method of the current invention.
DESCRIPTION OF THE PREFERRED EMBODIMENT
[0021] [0021]FIG. 1 shows a diagram of the physical problem of partial cavitation. FIG. 1 shows a radial cross section of an axisymmetric body 10 . Axis r represents the radius from the axis of body 10 . Axis x represents the length along the body 10 measured from a cavitator disk 12 . Although a cavitator disk is shown, the model can calculate cavities for cavitator cones as well as cavitator disks. Flow, U ∞ , is in the direction of arrow 14 . A cavity 16 is shown extending from the edge of the cavitator along the length of body 10 . The length of the cavity, l c , is shown by dimension arrows. Likewise, the length of the body, l b , is also shown by dimension arrows.
[0022] Body 10 extends beyond a cavity closure 18 . Cavity 16 is closed to the body 10 with a modified Riabouchinsky cavity termination wall. Cavity closure 18 can be positioned in either body conical section 22 or body cylindrical section 24 . The plane of cavity closure 18 is referenced in the following disclosure as an endplate.
[0023] Body 10 has a flat front area 20 followed by a conical section 22 and a cylindrical section 24 . The diameter of flat front area 20 should be less than or equal to the diameter of the cavitator disk 12 base.
[0024] The mathematical formulations in of this algorithm are based on using the cavitator diameter to remove dimensionality for all lengths and using the free stream velocity, U ∞ , to remove dimensionality for all velocities. Alternate formulations using standard units can also be developed.
[0025] The flow field is governed by Laplace's equation,
∇ 2 Φ=0 (1)
[0026] where Φ is the total potential which is the sum of free stream potential, φ ∞ , and disturbance potential, φ, giving:
Φ=φ ∞ +φ (2)
[0027] The free stream potential is the product of the velocity and the distance, x. Because the equation has been non-dimensionalized, the velocity is 1, and the free stream potential, φ ∞ , is x. The disturbance potential, φ, also obeys Laplace's equation, giving:
∇ 2 φ=0 (3)
[0028] The disturbance potential satisfies Green's third identity, yielding a Fredholm integral equation of the second kind along the cavitator, cavity, endplate and body. Thus, at any point, x, on the body-cavity surface, the disturbance potential can be computed from:
2 πφ ( x ) = ∯ S [ φ ( x ) ∂ ∂ n G ( x ; x ′ ) - ∂ ∂ n φ ( x ) G ( x ; x ′ ) ] S ( 4 )
[0029] where x' are the points where the sources and dipoles are distributed under the boundary element model;
[0030] S is the body-cavity surface; and
[0031] G(x,x') is the Green function.
[0032] The Green function is further identified as:
G ( x , x ′ ) = 1 x - x ′ ( 5 )
[0033] The dynamic condition on the cavity boundary is derived from Bernoulli's equation. Along the cavity surface, this can be written as:
p ∞ + 1 2 ρ U ∞ 2 = p c + 1 2 ρ U S 2 ( 6 )
[0034] where P ∞ is the free stream ambient pressure;
[0035] ρ is the free field fluid density;
[0036] p c is the pressure inside the cavity; and
[0037] U s is the flow velocity at the cavity surface.
[0038] The flow velocity at the cavity surface can be obtained from equation (6) giving:
U S = 1 + σ ( 7 )
[0039] where σ is the cavitation number which is defined as:
σ = p ∞ - p c 1 2 ρ U ∞ 2 ( 8 )
[0040] The kinetic boundary condition is that no flow crosses the body-cavity boundary,
∂ φ ∂ n = - n x ( 9 )
[0041] where n x is the axisymmetric body free-stream velocity power. The no net flux condition,
∯ S ∂ φ ( x ) ∂ n S = 0 ( 10 )
[0042] is also required to make the problem a determinate system.
[0043] Total drag is calculated by adding the drag coefficients. The pressure drag coefficient, C p , at {overscore (x)} is calculated as follows:
C p =1−U({overscore (x)}) 2 (11)
[0044] The pressure contribution to the drag coefficient may then be computed as:
C dp = 4 π ∯ S C p n x S ( 12 )
[0045] The viscous contribution to the drag coefficient along the wetted portions of the conical and cylindrical body areas is calculated using the International Towing Tank Conference equation given by Newman, Marine Hydrodynamics , MIT Press, Cambridge, Mass. 1980, for the friction coefficient, C f , at {overscore (x)} is as follows:
C f = 0.075 ( log 10 ( R ( x _ ) - 2 ) ) 2 ( 13 )
[0046] where R({overscore (x)}) is the local Reynolds number. The total viscous drag coefficient, C dv , is:
C dv = 4 π ∯ S C f s x S ( 14 )
[0047] The base drag coefficient, C db , which is the component of pressure drag associated with the base of the body is:
C db = 0.029 ( 2 b base ) 3 C dv , ( 15 )
[0048] where b base is the body radius at the base. The total drag coefficient is then given by
C d =C dp +C dv +C db . (16)
[0049] The panels are distributed along the cavitator, cavity, endplate, and cylindrical body section aft of the cavity, according to the partial floor method, known in the art. The partial floor method optimizes the number of panels in accordance with requirements for getting good convergence. Non-uniform panel spacing is used in many locations, in order to reduce the number of panels without reducing the accuracy of the solution.
[0050] During iteration, the end plate height is determined by integrating the cavity surface back from its detachment point on the cavitator, and the number and distribution of panels along the endplate changes according to the changes in the endplate height. Smaller panels are required at highly non-linear flow locations, such as the region near the cavitator. Panel distribution in the wetted body area after cavity closure 18 changes to keep the aspect ratio of the neighboring panels between 0.5 and 2.0, in order to ensure good accuracy of the results.
[0051] In following the method of the current invention, first an initial cavity is defined. An arbitrary initial cavity can be chosen as a cone extending from the cavitator edge to an assumed endplate height of 0.2 or 0.3 is sufficient for most cases. In this discussion, the endplate height is measured as the radial offset from the body surface to the last point of the cavity. By applying equation (4) on all panels along the cavity body surface, S, a system of equations is obtained. This system is solved for the disturbance potentials, φ, along the wetted portions of the boundary and on the Riabouchinsky endplate; the normal derivative of the disturbance potential along the cavity boundary; and the cavitation number.
[0052] The kinetic boundary condition given in equation (9) is applied along cavitator, endplate, and aft body to update the cavity shape. In order to update the cavity, the program calculates how much each panel has to be rotated to satisfy the no flow condition. The program starts with the first panel at the cavitator and shifts the aft most point of the panel in the radial direction which satisfies the calculated rotation. The panel is rotated with the aft most point. The foremost point of the next panel is then shifted to the same radius as the previous aft most point. This process is continued until the panel adjacent to the endplate is undated. The endplate height is adjusted to the aft most point of the aft cavity panel. The iteration continues until the kinetic boundary condition converges to within a tolerance, giving the cavity shape.
[0053] From the converged disturbance potential along S, the disturbance velocity components can be calculated:
u x = ∂ φ ∂ x and u r = ∂ φ ∂ r . ( 17 )
[0054] Referring now to FIG. 2, there is shown a flowchart of the current invention. In the input step 30 , geometric and other system parameter data including the estimated cavitation number, the estimated cavity length and the convergence criteria is read. The routine then distributes boundary element panels along the cavitator, cavity, endplate, body extension in the conical section, body extension in the horizontal section, and the aft body. The panels are distributed in order to reduce the number of panels and get an accurate result. In the initialize step 32 , the algorithm calculates the unit dipole and unit source functions and initializes matrices for the influence functions with known boundary values wherever applicable. The formulate equations step 34 formulates matrices for each panel using the disturbance potential equation (4) and no net flux condition given in equation (9). The solve equations step 36 solves the matrices created in the formulate equations step 34 in order to obtain the unknown disturbance potential along wetted body sources, normal distributions of disturbance potentials along cavity surfaces, and the cavitation number. The compute forces step 38 computes velocity components such as those in equation (17) and drag coefficients: including pressure drag, equation (12); viscous drag, equation (14); and base drag, equation (15) from the solved equations. In the update cavity step 40 , the cavity is updated from the computed forces using the kinetic boundary condition of equation (9). Convergence on cavity shape is checked in the converges decision step 42 . If the cavity is not converged, the initialize step 32 is executed to calculate influence functions for the updated cavity and next iteration thus begins. Once the cavity has converged, the compute parameters step 44 computes various output parameters of the converged solution which include pressure drag, viscous drag, base drag, total drag, cavitation number, cavity length, maximum cavity radius, length of cavity to maximum radius location. The output results step 46 then provides the location of the cavity written as coordinates and the cavity's disturbance potential, disturbance potential gradient, and pressure coefficient.
[0055] The basic algorithm enumerated above provides cavity shape and cavitation number based on an input cavity length. In order to obtain cavity shape and cavity length for an input cavitation number, the embodiment of FIG. 3 adds an additional series of iterations. The user inputs a cavitation number and an assumed cavity length. This embodiment follows the previous embodiment in converging on a new cavitation number, σ, for the assumed cavity length. In step 48 , if the new cavitation number is within a tolerance of the given cavitation number, parameters are computed, step 44 , and the results are provided, step 46 . Otherwise the embodiment proceeds to step 50 wherein the algorithm determines the relationship between the new cavitation number, σ, and the given cavitation number. In step 52 , cavity length is increased by a predetermined amount if the calculated cavitation number is lower than the initial cavitation number, and in step 54 the cavity length is decreased by a predetermined amount if the calculated cavitation number is greater than the initial cavitation number. The routine loops back to the initialize step 32 and recalculates the cavitation number for the new cavity length. Operation continues until the calculated cavitation number falls within a tolerance of the initial cavitation number, the cavity length has converged, as tested in step 48 .
[0056] Using this invention; partial cavitation for high-speed underwater bodies can be analyzed. As disclosed, the invention can analyze axisymmetrical bodies using two cavitator shapes, a disk and a cone; however, the invention can easily be modified to analyze other axisymmetric cavitator shapes. As disclosed the inventive method can converge on cavity length or cavitation number. Total drag is calculated by adding the pressure drag, viscous drag and base drag. The invention can also be utilized for studying the effects of body aft radius, body cone angle and body cone angle starting at the cavity closure if the closure is on conical section 22 . This method provides new information concerning the physics of cavitation which can be used in the design of cavitating vehicles.
[0057] In light of the above, it is therefore understood that within the scope of the appended claims, the invention may be practiced otherwise than as specifically described. | A method for calculating parameters about an axisymmetric body in a cavity is provided. The user provides data describing the body, a cavity estimate, and convergence tolerances. Boundary element panels are distributed along the body and the estimated cavity. Matrices are initialized for each panel using disturbance potentials and boundary values. Disturbance potential matrices are formulated for each panel using disturbance potential equations and boundary conditions. The initialized matrices and the formulated matrices are solved for each boundary panel to obtain panel sources, dipoles and cavitation numbers. Forces and velocities are computed giving velocity and drag components. The cavity shape is updated by moving each panel in accordance with the calculated values. The method then tests for convergence against a tolerance, and iterates until convergence is achieved. Upon completion, parameters of interest and the cavity shape are provided. This invention also allows determiniation of cavity shape for a cavitation number. | 5 |
BACKGROUND OF THE INVENTION
The present invention relates to a supply system for supercharged diesel engines, which system permits high power to be achieved for short periods of time.
One of the most important objectives of current motor vehicle technology is the reduction of consumption, both by reducing the weight of motor vehicles, by optimising the efficiency of the power units and, not least, by raising the transmission ratios.
This latter type of system, which gives excellent results from the point of view of fuel saving, involves on the other hand a significant loss of acceleration and this considerably detracts from the overall performance of the motor vehicle. At a particular disadvantage are vehicles equipped with diesel engines which, even if provided with supercharging, have a power sometimes equal but often less than the same models equipped with petrol engines, and with a greater overall weight.
SUMMARY OF THE INVENTION
The object of the present invention is to obtain a supply system for super-charged diesel engines which permits high power to be obtained for predetermined short periods of time for the purpose of increasing or at least maintaining unaltered, the qualities of acceleration and pickup of a motor vehicle having a high transmission ratio which is therefore favourable from the point of view of fuel consumption.
The said object is achieved by means of a supply system for supercharged diesel engines comprising:
a turbo compressor driven by exhaust gas from the engine;
a fuel delivery regulator connected to the injection pump and controlled by the pressure in the induction manifold, characterised by the fact that;
the fuel delivery regulator is provided with a device operable to significantly increase the delivery of fuel by the injection pump;
the accelerator pedal is coupled to a control operating the device with which the delivery regulator is provided in dependence on a predetermined position of the pedal itself.
BRIEF DESCRIPTION OF THE DRAWINGS
Further characteristics and advantages will become clearly apparent from the following description with reference to the attached drawings, provided by way of non limitative example, and in which:
FIG. 1 is a schematic view of an engine having a system according to the invention;
FIG. 2 is a partially sectioned view of the device illustrated in FIG. 1.
DETAILED DESCRIPTION OF THE INVENTION
With reference to the drawings, a diesel engine is generally indicated with the reference numeral 1, which engine can be either of the direct injection or indirect injection type and is provided with an exhaust manifold 2 which penetrates into the turbine 3 of a turbo compressor 4 provided with an exhaust 5 and connected to a compressor 6 which receives air through a duct 7 coming from the air filter 8. The compressor 6 delivers compressed air to an induction manifold 9.
An injection pump 10 connected to the engine is provided with a fuel delivery adaptation device 11 operating in dependence on the pressure in the induction manifold. This pressure is detected via a duct 12 connected to the manifold 9.
Details of the devive 11 which senses the supercharging power in the manifold are illustrated in FIG. 2. This device is formed by two superimposed chambers 13 and 14 which are separated by a resilient membrane 15. The upper of the two chambers is connected to the induction manifold by the duct 12 which has already been mentioned, whilst the lower chamber is open to the atmosphere through a hole 16. To the membrane 15 is connected, in a known way, a downwardly facing piston 17 sliding in a seat 18 and the profile of which has, in its median part, a groove 19 which joins with a frusto-conical part 20. A probe finger 21 is held in contact with the side of the piston by known means not illustrated.
A spring 22, co-axial with the piston, maintains the membrane 15 pressed upwardly with a predetermined thrust, whilst a second spring 23, shorter than the preceding one and also having a predetermined load, is positioned coaxially with the first, is provided with a cap 24 over its upper part and also rests, like the spring 22, on the lower wall of the chamber 14. On the upper wall of the fuel delivery regulator 11 there is located, in a central position, an electrically operated valve 25 actuating a piston 26 which, by passing through a hole 27 extends into the interior of the chamber 13 and is able to act on an end cap 28 connected to the membrane 15 and therefore to the piston 17 in such a way as to press the piston itself downwardly against the action of the springs 22 and 23.
The electrically operated valve 25 is controlled by means of a connection 29 from a control unit 30 which is operated when the accelerator 31 reaches a predetermined open position, which will generally be very close to its maximum or lower limit.
Operation of the device.
When the accelerator 31 has not passed the predetermined open position in its range of open positions between upper and lower limits, the operation of the device corresponds entirely and exactly to that of a normal supercharging system and will not be described since it is well known and in the capacity of any man skilled in the art.
However, when the accelerator 31 reaches the predetermined open position the device behaves in the manner described below.
The control unit 30 operates the electrically operated valve 25 for a short moment to displace the piston 26 which presses both the membrane 15 and the piston 20 downwardly via the end cap 28. The length of the piston 26 is calculated in such a way that the piston 20 is pressed downwardly sufficiently far for the probe finger 21 which slides on the side of the piston 20 to become located at the beginning of the slope of the groove 19. For this the piston 26 must exert a thrust such as to permit it to overcome the resistance exerted by the spring 23 on the membrane 15. The spring 23 in fact constitutes, via the end cap 24, a threshold which in normal operating conditions is not ever exceeded by in membrane and therefore always constitutes the end point of the stroke of the piston in normal operating conditions.
In these conditions the supercharging pressure in the induction manifold reaches very high values and/or in any case greater than those existing in the normal range of use of the engine in that the greater delivery of fuel effected by the pump as a consequence of the fact that the probe finger is located in the groove 19 causes an almost instantaneous increase in the temperature and pressure of the exhaust gases and therefore a greater capacity of the turbo compressor.
The high supercharging value is detected by the device 11 via the duct 12. Consequently, the membrane 15 will receive a strong downward thrust which will hold the membrane in the position reached by the action of the piston 26. In this way there will be a sudden high increase in the power provided by the engine.
In order not to shorten the life of the engine, these high powers will only be able to be used for short instants and this is easily obtainable for example by positioning in series on the duct 12 a three way-two position electrically operated valve 32 controlled simultaneously by the electrically operated valve 25 and provided with a predetermined delay time, which interrupts for several instants the connection between the induction manifold 9 and the chamber 13, connecting this latter to the atmosphere. In this way there will be obtained a sudden reduction in the pressure in the chamber 13 and the spring 23, returning to its extended position, will raise the piston making the finger probe move out from the groove and returning the fuel delivery to normal values.
It is intended that what is described above can be widely varied without by thus departing from the scope of the invention. | A supply system for supercharged diesel engines which has the purpose of obtaining high power for short periods of time without making it necessary to introduce changes to the engine, but simply by adding to a normal supercharging circuit a predetermined threshold on the fuel delivery regulator, a control operated by an electrically operated valve and controlled by the accelerator. | 5 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates generally to a device for actuating movable cams in a flat knitting machine and, more particularly, to a device for actuating movable cams in a flat knitting machine of the kind having a cam plate and several cams arranged thereon, which cams are movable in a direction substantially perpendicular to a plane of movement of the cam box.
2. Description of the Background
Flat knitting machines are known that have a cam plate and several cams arranged thereon, which cams are movable in a direction perpendicular to the plane of movement of the cam box. The cams are also movable perpendicularly to each of a number of grooves that are formed in a carrier and that cooperate with an engaging element, which run along such grooves. Each engaging element is mounted on a rod that is firmly attached to the respective cam involved, and the carrier is attached to a control shaft that is reversibly driven through predetermined angles.
There are various actuating approaches already known for this kind of flat knitting machine and such actuating procedures are generally divided into the use of mechanical actuating means on the one hand and electro-mechanical actuating means on the other. In both cases, however, the cams of the cam box used for such actuation purposes are generally movable perpendicularly to the plane of movement of the needles in flat knitting machines.
In the case of a purely mechanical device used to actuate the cams, the movement of the movable cams is brought about by fixed studs arranged at the machine end that operate upon the stroke reversal of the carriage, as it moves back and forth. In this fashion, the cams involved assume their desired positions by means of curved guides, which require expensive intermediate elements and other costly mechanical parts.
In the case of electromechanical devices used for the actuating of cams, a distinction must be made between those which use electromagnetic correcting elements and those that make use of stepping motors and the like. Furthermore, it should be noted that electromechanical solutions present a further advantage in that they are particularly applicable for flat knitting machines of the kind that have a variable carriage stroke.
In a system disclosed in German Patent Publication DE-OS No. 2,111,789, a separate electromagnet is installed for each movable cam. The electromagnet is arranged so that no forces result in the stroke direction of the electromagnet, in order to prevent the occurrence of unwanted disturbances to the knitting operation during operation of the machine.
Another solution to the movable cams problem is disclosed in German Patent Publication DE-OS No. 2,622,347, in which the cams cooperate with a number of disks having cam-contoured grooves. The disks are jointly arranged on a control shaft, which can be rotated into predetermined angular positions by means of a stepping motor. The actuation of the cams is accomplished individually or in groups by rotating the control shaft in a manner that is predetermined by the corresponding camcontoured grooves. This system has a particular disadvantage in that it is not suitable for a large number of movable cams, both because of the mechanical expense due to the number of parts and also to the large physical space that is required by this large number of cams. The space problem is particularly problematic if the cams must lie close together in that knitting machine.
OBJECTS AND SUMMARY OF THE INVENTION
Accordingly, it is an object of the present invention to provide a device for actuating movable cams in a flat knitting machine that can eliminate the above-noted defects inherent in the prior art.
Another object of this invention is to provide a device for actuating cams in a flat knitting machine in which the actuation of a relatively large number of cams, which are arranged centrally in the cam box can be designed with a substantially dense packing arrangement.
In accordance with an aspect of the present invention such device is provided that includes a drumshaped carrier on which grooves are formed on the peripheral surface thereof at an axial distance from one another and which have variable axial positions over the position of the drum. In this fashion, the axis of rotation of the drum is arranged perpendicularly to the plane of movement of the cam box and is located substantially centrally with respect to all movable cams.
The above and another objects, features, and advantages of the present invention will become apparent from the following detailed description of illustrated embodiments thereof to be read in conjection with the accompanying drawings, in which like reference numerals represent the same or similar elements.
BRIEF DESCRIPTION OF THE DRAWING
FIG. 1 is a top plan view of a cam box assembly of a flat knitting machine provided with a device according to an embodiment of the present invention for actuating cams;
FIG. 2 is a cross-sectional view taken along section lines II--II of FIG. 1, with one of the movable cams shown in detail;
FIG. 3 is a cross-sectional view taken along section lines III--III in FIG. 2, in which the elements are shown in a somewhat simplified form;
FIG. 4 is a schematic representation of the positions that a drum cam assume;
FIG. 5 is a development of the peripheral surface of the drum corresponding to a position c, as shown in FIG. 4;
FIG. 6 is a top plan view of a lower control disk employed in the embodiment of FIG. 2;
FIG. 7 is a top plan view of an upper control disk employed in the embodiment of FIG. 2; and
FIG. 8 is a cross-sectional view of two drums with a common power transmission agent, such as a stepping motor.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
In FIG. 1, a front cam plate 3 facing the needle bed of a cam box 1, as found in a flat knitting machine, is shown in top plan view. It is to this front cam plate 3 that the individual elements of the device for actuating the movable cams are attached.
These cams are both firmly attached and movably arranged, that is, they are movable, and the cams in the currently common combined cam box 1 are both for knitting and stitch transfers. The cams are arranged symmetrically in cam box 1, with reference to a longitudinal unit plane 2.
The cams 31, 32, 33, 34, 35, 36, are firmly attached to cam plate 3 and serve mainly as safety elements and also to form the different cam paths with the movable cams. The stitch cams 37, 37', for adjusting the stitch size, are movable parallel to the plane of movement of the needles. Stitch cams 37, 37', are arranged in cam box 1 in a known way and do not have any connection with the device provided by the present invention. Stitch cams 37, 37' work independently of the elements provided by the present invention.
Guard cams 38, 38' are movable both parallel and perpendicular to the plane of movement of the needles and as will be set forth below, these elements are connected with the device according to the present invention only in an indirect manner.
In regard to a course direction A of a carriage, not shown in detail, on which cam box 1 is connected with cam plate 3, functional and structural distinctions are made among a rising cam 4, a first closing cam 5, a second closing cam 6, a protuberant cam 7, and a reception cam 8. It will be understood that corresponding cams 4', 5', 6', 7', and 8' are provided for the course moving in the opposite direction.
Each of the above-mentioned movable cams is firmly attached to a respective, generally bar-shaped, guidance part 9, as shown in FIGS. 2 and 3, that is arranged substantially perpendicularly to cam plate 3. An activation pin 11 engages in a respective one of a number of circular grooves 12 formed in drum 13, and pin 11 is located at an end 10 of increased dimensions arranged at one end of bar 9 that is provided for the respective cam involved. These movable cams can assume two precisely determined positions upon each passage of the cam box, that is, a working position in which the butts of knitting elements (not shown) can engage, and a nonworking position, in which the butts of such knitting elements cannot engage.
A number of grooves 12 are arranged on the periphery of the drum 13 that is mounted for rotary motion on a cam plate 3 and that has its center 14 located within the effective radius of the cams, as represented in FIG. 1, for example. Drum 13 is shown in FIG. 2 as mounted by ball bearings on a shaft 25 that is attached to a housing 24. Housing 24 also contains guides for bars 9 that bear the cams, and housing 24 is mounted on cam plate 3, as shown in FIG. 2.
Referring now to FIG. 5, which is a development of the periphery of connection drum 13, grooves 12 are subdivided into tracks, which are located in several planes parallel to the axis of rotation 14 of drum 13.
The movable cams are each assigned to a respective individual track in such a way that a corresponding activation pin 11 engages in the corresponding respective groove 12. In the embodiment shown herein, a total of ten cams are attached, which make use of a total of five paths or tracks 12 on connection drum 13.
Turning back to FIG. 2, drum 13 is mounted to be rotated by a power transmission agent, which in this embodiment is a stepping motor 17, by means of inner gear rim 15 and a driving pinion 16, which is mounted on the drive shaft of stepping motor 17. By use of stepping motor 17 it is possible to shift drum 13 by definite and precise angular amounts. The active length of groove 12 for each cam amounts to an angular extent of 144° on the periphery of drum 13 and, in this embodiments, requires 160 actuation steps of motor 17 to achieve the desired result. The axial formation of grooves 12 corresponds to stroke 30, that is, the extent of travel to be transmitted to the movable cam through pin 11, as represented in FIGS. 2 and 5.
As shown in FIG. 2, to control the precise and correct angular position of drum 13, two control disks 18, 19 are attached at the upper end of drum 13, and these disks 18, 19 are scanned without contact by proximity detectors or switches 20, 21, 22, 23. Proximity switches are attached to housing 24 by respective mounting brackets 48, 49, 50. These switches may be comprised of magnetic or optical detectors. The shape of the lower control disk is shown in FIG. 6 and includes two notches 26 and 27 in its periphery. Similarly, upper control disk 19 is shown in FIG. 7 and includes notches 28 and 29 in its periphery. The combination of these two disks 18, 19 make possible a definite recognition of different sector positions about drum 13. Each disk is divided in half by a diametric line and each half includes sectors designated as a, b, c, d, and e, so that in a given case for the three switches 20, 21, and 22 being arranged mutally separated by 90° on the periphery of the disk, it is possible to recognize the desired sector. Notches 28 on the upper half of control disk 19 cooperate with switch or detector 23 and aid in making the recognition of the precise position of drum 13 possible.
The device for actuating movable cams in a flat knitting machine according to the present invention as described above operates as follows. Stepping motor 17 is activated at one of the stroke reversal points of the carriage that is moving back and forth, in which one or more cam boxes 1 that have movable cams is accommodated, whereby a number of rotary steps are performed in either a clockwise or counterclockwise position. More specifically, one rotary turning causes drum 13, which is connected to stepping motor 17 by means of gears 15, 16 to either place the attached means in or out of activity individually or in a certain combination, according to the specific design of grooves 12, arranged on the periphery of drum 13. It will be understood that the process described is also correspondingly repeated at the opposite stroke reversal point of the knitting carriage as it moves back and forth.
For example, in position or sector c out of the five possible angle positions a, b, c, d, e of drum 13, cams 5, 5' are withdrawn out of activity, but on the other hand, cams 6, 6', 4, 4', 8, 8', and 7, 7' are lowered and are active.
In position b of drum 13, cams 6, 6', 4, 4', 8 and 7' are withdrawn and cams 5, 5', 8' and 7 are lowered and are active. This causes the needles selected in direction of course A to reach cam path 42 with full-butt height to accomplish stitch transfer, but on the other hand, the needles selected with the half-butt height reach cam path 41 for stitch reception.
At position d of drum 13, cams 6, 6', 4, 4', 8' and 7 are withdrawn and cams 5, 5', 8, and 7' are lowered, which leads the needles selected to reach cam path 42' with full-butt height for stitch transfer in direction of course A' but, on the other hand, the needles selected with half-butt height reach cam path 41' for stitch reception.
Position a of connection drum 13 corresponds to position b, with the difference that protuberance cam 7' is also actuated for stitch transfer. Similarly, position e is the analog of position d.
It must be understood that because a flat knitting machine with individual needle selection is involved in the above-described embodiment, so-called pressure cams 45, 46, 47 are also contained in the cam box. These cams serve to permit additional selection combinations, for example the tucking position of the needles.
If adjacent cam boxes are equipped with more limited stitch transfer possibilities, and the number of movable cams is consequently smaller, it is possible to drive drums 13 of at least two cam boxes located one beside each other with a common stepping motor 17. This arrangement is shown in FIG. 8 in which it is seen that by use of drive connections 16, 51, 52, 53, and 54 which are slip-less gear wheels and gear belts, that is, toothed timing belts that will not slip. Accordingly, this arrangement is sufficient to require control disks 18, 19 and proximity switches 20, 21, 22, 23 on only one of the two drums, as shown in FIG. 8 on the drum at the left hand side of the drawing.
The above description is given on a single preferred embodiment of the invention, but it will be apparent that many modifications and variations could be effected by one skilled in the art without departing from the spirit or scope of the novel concepts of the invention, which should be determined by the appended claims. | A device for actuating movable cams for use on a flat knitting machine that includes several cams arranged on a cam plate, in which the cams are movable in a direction perpendicular to the plane of movement of the cam box, contains a drum having an axis of rotation that is perpendicular to the plane of movement of the cam box and that is located substantially central relative to all movable cams. The drum includes grooves in the peripheral portion thereof at axial distances from one another, which grooves have variable axial positions over the periphery of the drum. A corresponding engaging part rides in a respective groove and the drum is rotated by a drum mechanism through definite angular amounts so that cams are placed in or out of activity at a stroke of the engaging part in the groove by means of connecting bars assigned to each of the engaging parts riding in the grooves on the drum. | 3 |
CROSS-REFERENCE TO RELATED APPLICATION
This application is a continuation of application Ser. No. 10/066/967 filed Feb. 4, 2002, now U.S. Pat. No. 7,146,981.
BACKGROUND
1. Field of the Invention
This invention is directed to methods and apparatuses for treating the pharyngeal wall of a patient. More particularly, this invention pertains to method and apparatus for treating a pharyngeal wall area as part of a sleep apnea treatment.
2. Description of the Prior Art
Sleep apnea and snoring are complex phenomena. Commonly assigned U.S. Pat. No. 6,250,307 describes various prior techniques and discloses a novel treatment for such conditions (including a permanent palatal implant).
These prior art teachings include Huang, et al., “Biomechanics of Snoring”, Endeavour , p. 96-100, Vol. 19, No. 3 (1995). That publication estimates that up to 20% of the adult population snores habitually. Snoring can be a serious cause of marital discord. In addition, snoring can present a serious health risk to the snorer. In 10% of habitual snorers, collapse of the airway during sleep can lead to obstructive sleep apnea syndrome. Id. In addition to describing a model for palatal flutter, that publication also describes a model for collapse of the pharyngeal wall.
Notwithstanding efforts have been made to treat snoring and sleep apnea. These include palatal treatments such as electrical stimulation of the soft palate. See, e.g., Schwartz, et al., “Effects of electrical stimulation to the soft palate on snoring and obstructive sleep apnea”, J. Prosthetic Dentistry , pp. 273-281 (1996). Devices to apply such stimulation are described in U.S. Pat. Nos. 5,284,161 and 5,792,067. Such devices are appliances requiring patient adherence to a regimen of use as well as subjecting the patient to discomfort during sleep. Electrical stimulation to treat sleep apnea is discussed in Wiltfang, et al., “First results on daytime submandibular electrostimulation of suprahyoidal muscles to prevent night-time hypopharyngeal collapse in obstructive sleep apnea syndrome”, International Journal of Oral & Maxillofacial Surgery , pp. 21-25 (1999).
Surgical treatments for the soft palate have also been employed. One such treatment is uvulopalatopharyngoplasty (UPPP) where about 2 cm of the trailing edge of the soft palate is removed to reduce the soft palate's ability to flutter between the tongue and the pharyngeal wall of the throat. See, Huang, et al., supra at 99 and Harries, et al., “The Surgical treatment of snoring”, Journal of Laryngology and Otology , pp. 1105-1106 (1996) which describes removal of up to 1.5 cm of the soft palate. Assessment of snoring treatment is discussed in Cole, et al., “Snoring: A review and a Reassessment”, Journal of Otolaryngology , pp. 303-306 (1995). Huang, et al., propose an alternative to UPPP which proposal includes using a surgical laser to create scar tissue on the surface of the soft palate. The scar is to reduce flexibility of the soft palate to reduce palatal flutter. RF ablation (so-called Somnoplasty as advocated by Somnus Technologies) is also suggested to treat the soft palate. RF ablation has also been suggested for ablation of the tongue base.
In pharyngeal snoring and sleep apnea, the pharyngeal airway collapses in an area between the soft palate and the larynx. One technique for treating airway collapse is continuous positive airway pressure (CPAP). In CPAP air is passed under pressure to maintain a patent airway. However, such equipment is bulky, expensive and generally restricted to patients with obstructive sleep apnea severe enough to threaten general health. Huang, et al. at p. 97.
Treatments of the pharyngeal wall include electrical stimulation is suggested in U.S. Pat. No. 6,240,316 to Richmond et al. issued May 29, 2001, U.S. Pat. No. 4,830,008 to Meer issued May 16, 1989, U.S. Pat. No. 5,158,080 to Kallok issued Oct. 27, 1992, U.S. Pat. No. 5,591,216 to Testerman et al. issued Jan. 7, 1997 and PCT International Publication No. WO 01/23039 published Apr. 5, 2001 (on PCT International Application No. PCT/US00/26616 filed Sep. 28, 2000 with priority to U.S. Ser. No. 09/409,018 filed Sep. 29, 1999). U.S. Pat. No. 5,979,456 to Magovern dated Nov. 9, 1999 teaches an apparatus for modifying the shape of a pharynx. These teachings include a shape-memory structure having an activated shape and a quiescent shape. Dreher et al., “Influence of nasal obstruction on sleep-associated breathing disorders”, So. Laryngo-Rhino-Otologie, pp. 313-317 (June 1999), suggests using nasal stents to treat sleep associated breathing disorders involving nasal obstruction. Upper airway dilating drug treatment is suggested in Aboubakr, et al., “Long-term facilitation in obstructive sleep apnea patients during NREM sleep”, J. Applied Physiology, pp. 2751-2757 (December 2001).
Surgical treatments for sleep apnea are described in Sher et al., “The Efficacy of Surgical Modifications of the Upper Airway in Adults with Obstructive Sleep Apnea Syndrome”, Sleep , Vol. 19, No. 2, pp. 156-177 (1996). Anatomical evaluation of patients with sleep apnea or other sleep disordered breathing are described in Schwab, et al., “Upper Airway and Soft Tissue Anatomy in Normal Subjects and Patients with Sleep-Disordered Breathing”, Am. J. Respir. Crit. Care Med ., Vol. 152, pp. 1673-1689 (1995) (“Schwab I”) and Schwab et al., “Dynamic Upper Airway Imaging During Awake Respiration in Normal Subjects and Patients with Sleep Disordered Breathing”, Am. Rev. Respir. Dis ., Vol. 148, pp. 1385-1400 (1993) (“Schwab II). In Schwab I, it is noted that apneic patients have a smaller airway size and width and a thicker lateral pharyngeal wall. For reviews of pharyngeal wall thickness and other structure and obstructive sleep apnea, see, also, Wheatley, et al., “Mechanical Properties of the Upper Airway”, Current Opinion in Pulmonary Medicine, pp. 363-369 (November 1998); Schwartz et al., “Pharyngeal airway obstruction in obstructive sleep apnea: pathophysiology and clinical implication”, Otolaryngologic Clinics of N. Amer., pp. 911-918 (December 1998); Collard, et al., “Why should we enlarge the pharynx in obstructive sleep apnea?”, Sleep, (9 Suppl.) pp. S85-S87 (November 1996); Winter, et al., “Enlargement of the lateral pharyngeal fat pad space in pigs increases upper airway resistance”, J. Applied Physiology, pp. 726-731 (September 1995); and Stauffer, et al., “Pharyngeal Size and Resistance in Obstructive Sleep Apnea”, Amer. Review of Respiratory Disease, pp. 623-627 (September 1987)
SUMMARY OF THE INVENTION
According to one aspect of the present invention, methods and apparatuses are disclosed for treating a pharyngeal airway having a pharyngeal wall of a patient at least partially surrounding and defining said airway. The method includes inserting an expander member into the airway and positioning an active portion of the expander member in opposition to portions of the wall to be treated. The expander member is activated to urge the wall portions outwardly to an outwardly displaced position. The expander member is then deactivated while leaving the wall portions in the outwardly placed position and the expander member is removed from said airway. A further aspect of the invention includes stabilization of at least a portion of the pharyngeal wall in the outwardly placed position after compression of portions of the wall.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows, in cross-section, a naso-pharyngeal area of an untreated patient;
FIG. 2 is the view of FIG. 1 with the soft palate containing an implant in the form of a bolus of micro-beads deposited in a linear path;
FIG. 3 is a frontal view of the patient of FIG. 3 showing an alternative embodiment with micro-beads deposited as spherical deposits;
FIG. 4 is a schematic representation showing a patch for delivering a bolus of micro-beads through a plurality of needles;
FIG. 5 is a schematic cross-sectional view (taken generally along line 5 - 5 in FIG. 2 ) of a pharyngeal airway at a position in a person with the airway defined by opposing portions of a pharyngeal wall and a base of a tongue;
FIG. 6 is the view of FIG. 5 with a first embodiment of an expander member in position prior to activation;
FIG. 7 is the view of FIG. 6 following activation of the expander member to compress portions of the pharyngeal wall;
FIG. 8 is a side-sectional view of compression pads used in the expander member of FIG. 7 ;
FIG. 9 is the view of FIG. 7 following deactivation and removal of the expander member and showing retention of the pharyngeal wall in an expanded state;
FIG. 10 is the view of FIG. 6 showing an alternative embodiment of the invention;
FIG. 11 is the view of FIG. 6 showing a further alternative embodiment of the invention;
FIG. 12 is the view of FIG. 6 showing a still further alternative embodiment of the invention;
FIG. 13 is a schematic cross-sectional view (taken generally along line 13 - 13 in FIG. 2 ) of a pharyngeal airway at a position in a person distal to the base of the tongue and with the airway defined by the pharyngeal wall;
FIG. 14 is the view of FIG. 13 with a further embodiment of an expander member positioned in the airway in a deactivated state;
FIG. 15 is the view of FIG. 14 with the expander member shown activated compressing the pharyngeal wall;
FIG. 16 is the view of FIG. 15 following deactivation and removal of the expander member and showing retention of the pharyngeal wall in an expanded state;
FIG. 17 is a sectional schematic view of a compressed portion of tissue defining, in part, a pharyngeal airway and stabilized by a biocompatible material in the tissue of the compressed portion;
FIG. 18 is the view of FIG. 17 with the compressed tissue stabilized by suture material;
FIG. 19 is the view of FIG. 17 but with the tissue not being compressed and being stabilized by a suture material;
FIG. 20 is a side-sectional schematic view of a suture material having resorbable and non-resorbable portions;
FIG. 21 is the view of FIG. 18 with the suture material of FIG. 20 prior to resorption of the resorbable portions of the suture material; and
FIG. 22 is the view of FIG. 21 with the suture material of FIG. 20 following resorption of the resorbable portions of the suture material.
DESCRIPTION OF THE PREFERRED EMBODIMENT
A. Physiology Background
Referring now to the several drawing figures, in which identical elements are numbered identically throughout, a description of a preferred embodiment of the present invention will now be provided.
The disclosures of U.S. Pat. No. 6,250,307 and PCT International Publication No. WO 01/19301 (PCT/US00/40830) are incorporated herein by reference.
FIG. 1 shows, in cross-section, a naso-pharyngeal area of an untreated patient. FIG. 1 shows the nose N, mouth M and throat TH. The tongue T is shown in an oral cavity OC of the mouth. A hard palate HP (containing a bone B) separates the oral cavity OC from the nasal cavity NC. The nasal concha C (soft tissue which defines, in part, the nasal sinus—not shown) resides in the nasal cavity NC.
The soft palate SP (a muscle activated soft tissue not supported by bone) depends in cantilevered manner at a leading end LE from the hard palate HP and terminates at a trailing end TE. Below the soft palate SP, the pharyngeal wall PW defines the throat passage TP. A nasal passage NP connects the nasal cavity NC to the pharyngeal wall PW. Below an epiglottis EP, the throat passage TP divides into a trachea TR for passing air to the lungs and an esophagus ES for passing food and drink to the stomach.
The soft palate SP is operated by muscles (not separately shown and labeled) to lift the soft palate SP to urge the trailing edge TE against the rear area of the pharyngeal wall PW. This seals the nasal cavity NC from the oral cavity OC during swallowing. The epiglottis EP closes the trachea TR during swallowing and drinking and opens for breathing.
For purposes of this disclosure, the nasal cavity NC, oral cavity OC and throat passage TP are collectively referred to as the naso-pharyngeal area of the patient (defining, in part, the pharyngeal airway PA in FIGS. 5 and 13 ) with the area including the various body surfaces which cooperate to define the nasal cavity NC, oral cavity OC and throat passage TP. These body surfaces include outer surfaces of the nasal concha C, the upper and lower surfaces of the soft palate SP and outer surfaces of the pharyngeal wall PW. Outer surfaces means surfaces exposed to air. Both the upper and lower surfaces of the soft palate SP are outer surfaces.
Snoring can result from vibration of any one of a number of surfaces or structures of the naso-pharyngeal area. Most commonly, snoring is attributable to vibration of the soft palate SP. However, vibratory action of the nasal concha C and the pharyngeal wall PW can also contribute to snoring sounds. It is not uncommon for vibratory action from more than one region of the naso-pharyngeal area to contribute to snoring sounds. Sleep apnea can result from partial or full collapse of the naso-pharyngeal wall during sleep.
FIG. 5 shows a schematic representation of a cross-section of a throat with the pharyngeal airway PA defined by the pharyngeal wall PW and the tongue T. The anterior-posterior axis is labeled AP to assist in discerning the orientation. The pharyngeal wall PW is shown as including the left lateral pharyngeal wall LLPW, right lateral pharyngeal wall RLPW and posterior pharyngeal wall PPW.
B. Disclosure of Prior Application
In addition to disclosing the teachings of U.S. Pat. No. 6,250,307 and the teachings of selected embodiments of PCT International Publication No. WO 01/19301 (both incorporated herein by reference), commonly assigned and co-pending patent application U.S. Ser. No. 09/636,803, filed Aug. 10, 2000, which is hereby incorporated by reference in its entirety, describes techniques for stiffening tissue of the pharyngeal airway with a bolus of particulate matter. FIGS. 2 and 3 show are taken from the '803 application and show an implant 10 as a bolus of particulate matter. An example of such particulate matter would be micro-beads. An example of such is taught in U.S. Pat. Nos. 5,792,478 and 5,421,406. These patents teach carbon-coated metallic or ceramic particles having cross-sectional dimensions of between 100 and 1,000 microns. The particles are carried in a fluid or gel. These patents state that upon insertion into body tissue, the particles do not migrate significantly and, apparently due to fibrotic response, the tissue into which the particles are injected stiffens.
The particles of U.S. Pat. Nos. 5,792,478 and 5,421,406 are one example of particles for stiffening injection. Such particles can also include ceramic particles or pure carbon or other bio-compatible particles. The particles can be carried in a liquid or gel medium. The particles can have multi-modal particle size distributions (i.e., a mix of two or more sizes of particles with the smaller particles filling interstitial spaces between larger particles).
The bolus 10 of particles can be applied by a needle to inject the bolus 10 into the soft palate SP. The bolus can be the same volume as the volume of the implants 20 of FIGS. 8 and 9 of U.S. Pat. No. 6,250,307. With reference to FIG. 3 , a multiple of bolus injections can be made in the soft palate resulting in deposition of generally spherical deposits 10 ′ of particles. Alternatively, an injecting needle can be withdrawn while simultaneously ejecting particles for the bolus 10 ( FIG. 2 ) to be deposited in a line similar in dimensions to the implants 20 of FIGS. 8 and 9 of U.S. Pat. No. 6,250,307.
The foregoing emphasizes the use of implants to stiffen the soft palate SP. Implants 10 can be placed in any of the tissue of the naso-pharyngeal area (e.g., the concha C, soft palate SP or pharyngeal wall PW) to treat snoring. Also, such a treatment can stiffen the tissue of the throat and treat sleep apnea resulting from airway collapse by stiffening the airway.
While a needle deposition of a bolus of particles may be preferred, the bolus can be applied in other manners. FIG. 4 (which is a reproduction of FIG. 16 of the '803 application) illustrates deposition of particulates through a patch 12 having a volume 14 containing such micro-beads 16 .
One side 12 a of the patch 12 contains an array of micro-needles 18 communicating with the volume 14 . The needles 18 may be small diameter, shallow penetration needles to minimize pain and blood. Examples of shallow, small diameter needles are shown in U.S. Pat. No. 5,582,184 to Erickson et al. Placing the surface 12 a against the tissue (e.g., the pharyngeal wall PW as shown in FIG. 4 ), the needles 18 penetrate the outer surface of the tissue PW. The patch 12 can then be compressed (by finger pressure, roller or the like) to eject the beads 16 from the volume 14 through the plurality of needles 18 . The patch 12 can be provided with interior dividing walls (not shown) so that some of the volume of beads 16 is ejected through each needle 18 . The side 12 a acts as a stop surface to ensure control over the penetration depth of the needles 18 to reduce risk of undesired puncture of underlying structures.
Stiffening of the naso-pharyngeal tissue provides structure to reduce vibration and snoring. Such structure reduces airway collapse as a treatment for sleep apnea.
C. Pharyngeal Wall Compression
FIGS. 5-16 show various methods and apparatus for enlarging the pharyngeal airway PA. As will be described, further disclosure is made for stiffening the tissue or maintaining the enlarged airway size.
FIG. 6 is the view of FIG. 5 showing an expander member 20 positioned within the pharyngeal airway PA for the purpose of treating the pharyngeal wall PW. As will become apparent, the treatment includes enlargement of the pharyngeal airway PA by urging at least portions of the pharyngeal wall PW outwardly. In the embodiment of FIG. 6 , the right and left lateral pharyngeal wall portions RLPW, LLPW are being urged outwardly to increase the area of the airway PA.
The expander member 20 includes left and right supports 22 positioned opposing the right and left lateral pharyngeal wall portions RLPW, LLPW. Compression pads 24 are carried on the supports 22 and in direct opposition to the right and left lateral pharyngeal wall portions RLPW, LLPW. The supports 22 are maintained in fixed spaced apart relation by a spacer bar 26 .
While not shown in the drawings, the spacer bar 26 can be adjustable to permit a physician to modify the spacing between the supports 22 and to permit narrowing the spacing between the supports 22 to facilitate ease of placement of the expander member 20 in the airway PA at a desired treatment area. Preferably, the pads 24 and supports 22 have a length (distance parallel to the longitudinal axis of the airway PA) greater than a width (distance parallel to the opposing surface of the wall PW as indicated by W in FIG. 6 ) to treat an extended length of the wall PW. For example, the pads 24 and supports 22 could be about two centimeters long.
The compression pads 24 are inflatable bladders connected by a tube 28 ( FIG. 8 ) to a source of a pressurized fluid (not shown). Admission of pressurized fluid into the bladders 24 causes the bladders to enlarge urging the right and left lateral pharyngeal wall portions. RLPW, LLPW outwardly as illustrated in FIG. 7 . The compression of the tissue of the patient could be compression of the pharyngeal wall PW or compression of tissue surrounding the pharyngeal wall PW (for example, fatty pads). After the compression, the pads 24 are deflated and the expander member 20 is removed from the airway PA as illustrated in FIG. 9 leaving compressed right and left lateral pharyngeal wall portions RLPW, LLPW and an enlarged cross-sectional area of the pharyngeal airway PA.
In addition to compressing the walls of the pharyngeal airway PA, the compressed walls may be stabilized in a compressed state to ensure longer lasting retention of the therapeutic benefits of the enlarged airway PA. This stabilization can include injecting a bio-adhesive or bio-sealants into the tissue adjacent the treated portions of the pharyngeal wall.
An example of bio-adhesives includes cyanoacrylates. Without intending to be a limiting example, these include 2-octyl cyanoacrylate and 2-butyl cyanoacrylate. The 2-octyl cyanoacrylate is developed by Closure Medical Corp., Raleigh, N.C., USA for use to treat topical skin wounds, oral cancers and periodontal disease. It may last 1-2 weeks with faster absorbing products in development. The 2-butyl cyanoacrylate is used as a skin protectant and dental cement and is available from GluStitch, Inc., Delta, BC, Canada
Biocompatible adhesives also include surgical adhesives such as those developed by CryoLife International, Inc., Kennesaw, Ga., USA whose product is composed of purified bovine serum albumin (45%) and cross-linking agent glutaraldehyde (10%). Similar formulations include natural proteins (e.g., collagen, gelatin) with aldehyde or other cross-link agents.
Such bio-sealants may be fibrin sealants. Examples include blood-derived products (e.g., TISSEEL™ distributed by Baxter Corp., Deerfield, Ill., USA). Other examples of coatings include hydrogel coatings. An example of these include a photo-curing synthetic sealant developed by Focal, Inc., Lexington, Mass., USA which can adhere to moist or dry tissue and is highly flexible and elastic. This sealant may be absorbable over short or long terms. The sealant is currently used to treat air leaks associated with lung surgery. Other coatings include denture adhesives approved for use in humans.
From the foregoing, it can be seen there are a wide variety of adhesives and other coatings suitable for use with the present invention. The foregoing lists are intended to be illustrative and not exhaustive.
With the description given with respect to FIGS. 6-9 , the bio-stabilizer can be injected into the compressed regions of tissue adjacent the right and left pharyngeal wall. For example, the material can be injected into the compressed portions of the right and left lateral pharyngeal wall portions RLPW, LLPW (mucosal or sub-mucosal or muscular tissue) or into compressed tissue behind the right and left pharyngeal walls, such as compressed fatty tissues. The expander 20 can be left in place while the adhesive as least partially sets such that when the expander 20 is removed, the adhesive helps retain the compressed right and left lateral pharyngeal wall portions RLPW, LLPW in a compressed state.
Bio-adhesives degrade and the therapeutic benefit of the bio-adhesives can be lost over time. Accordingly, a still further embodiment of the present invention includes injecting a fibrosis-inducing agent into the compressed tissue. The fibrosis-inducing agent induces a fibrotic response of the tissue to stiffen the tissue and helping to retain the tissue in a compressed state.
It will be appreciated that the fibrosis-inducing agent may be used in conjunction with the bio-adhesive or the bio-adhesive and fibrosis-inducing agents can be used separately. In the preferred embodiment the fibrosis-inducing agent will be substantially non-biodegradable so as to provide a long lasting, chronic effect maintaining the compressed state of the pharyngeal wall PW.
By way of non-limiting example, a fibrosis-inducing material may be microbeads as described above. While microbeads may be a preferred embodiment, alternative techniques for inducing fibrosis can be in the form of placement in the compressed tissue of polyester material or other foreign bodies which induce a fibrotic response.
In addition to the adhesives or fibrosis-inducing agents, drugs may be admitted into the tissue. Drugs may be injected directly or in microspheres.
FIG. 8 illustrates an embodiment for injecting adhesives or microbeads into the compressed tissue by the use and placement of micro needles 30 on a side of the bladder 24 opposing the tissue similar to the embodiment of FIG. 4 . The fluid from the bladder 24 through the needles 30 contains the bio-adhesives and the microbeads. The micro needles 30 can be of various lengths to vary the depth of distribution of the adhesives and the microbeads.
FIGS. 10-12 show alternative embodiments of the present invention. Elements having functions in common with the fore-going embodiment are numbered identically with the addition of a suffix (“a”, “b” or “c”) to distinguish the embodiments.
In FIGS. 6 and 7 , compression members 24 are shown only opposing the right and left lateral pharyngeal wall portions RLPW, LLPW. In FIG. 12 , four compression members 24 a are shown to cover a wider area of the right and left lateral pharyngeal wall portions RLPW, LLPW. In FIG. 11 , three compression members 24 b are shown for compressing not only the right and left lateral pharyngeal wall portions RLPW, LLPW but also the posterior pharyngeal wall PPW. In FIG. 10 , an arcuate and continuous compression member 24 c is shown for compressing the entire pharyngeal wall PW.
FIGS. 13-15 illustrate use of the method of the present invention in a different region of the pharyngeal airway PA. With respect to FIGS. 6-12 , the embodiments of the invention are shown in use in that portion of the pharyngeal airway PA which is defined in part by the base of the tongue T. Further distal into the pharyngeal airway PA, the pharyngeal airway PA is defined by the pharyngeal wall PW as illustrated in FIG. 13 . The present invention is also applicable to treatment of the naso-pharynx NP ( FIG. 1 ) in which case the airway is defined by lateral and posterior pharyngeal walls and opposing surfaces of the palate. Since this is similar to the shown applications, separate illustrations need not be provided.
FIG. 14 shows a circular airway expander member 20 ′ having a circular support 22 ′ and a circular bladder 24 ′. Since the support 22 ′ is annular-shaped, an unobstructed airway PA remains to permit respiration by the patient during treatment. FIG. 15 shows the device with the bladder 22 ′ in an expanded state to cause compression of the pharyngeal wall PW. FIG. 16 shows the compressed pharyngeal wall following removal of the expander member 20 ′.
FIGS. 17-22 illustrate various examples of techniques for stabilizing the pharyngeal wall PW. FIG. 17 illustrates a region of compressed tissue CT impregnated with a stabilizing material 40 (e.g., adhesive, sealant or microbeads).
The compressed tissue CT may be compressed mucosal tissue or may be compressed muscular tissue. Also, the compressed tissue CT may be compressed fatty pads adjacent the pharyngeal wall PW.
Stabilization could result from a chemical agent (e.g., a sclerosing agent) or by application of energy (e.g., radiofrequency ablation) or any other means (e.g., cryogenic ablation). It will be appreciated that not all of these techniques need provide a permanent stabilization and some of these techniques may result in remodeling over time. Subsequent treatments may then be provided.
FIG. 18 illustrates a mechanical stabilization using suture material 42 to hold the compressed tissue in a compressed state. The suture material may be resorbable or non-resorbable. FIG. 19 is similar to FIG. 18 but the pharyngeal wall is not compressed. Instead, the pharyngeal wall is stabilized by sutures 44 to underlying structure US (e.g., to underlying bucco-pharyngeal fascia, prevertebral fascia, anterior longitudinal ligament or vertebral bodies). Attachment to such bodies may also occur following compression. Stabilization can result from tacking to any sub-mucosal area surrounding the pharyngeal airway.
FIGS. 20-22 illustrate a variation of FIG. 18 where the suture material 46 includes a short non-resorbable core 48 (e.g., poly ester tetrapthalate—PET) covered by a longer outer coating 50 of resorbable suture material. Immediately after the implantation, only the resorbable ends extend out of the pharyngeal wall PW into the airway PA and are tied off (see FIG. 21 ). Following resorption, the non-resorbable portion 48 is fully recessed behind the wall PW as shown in FIG. 22 to limit possibility of later migration of the non-resorbable core 48 into the airway PA. In the foregoing, the term “suture” is not intended to be limited to a thread-like material but can include clips or any other closure mechanism.
The foregoing describes numerous embodiments of a method and apparatus to treat a pharyngeal wall. Having described the invention, alternatives and embodiments may occur to one of skill in the art. For example, a physician may stabilize all or a portion of the pharyngeal wall within the teachings of the foregoing with conventional surgical instruments. It is intended that such modifications and equivalents shall be included within the scope of the following claims. | A patient's pharyngeal wall is treated by inserting an expander member into the airway and positioning an active portion of the expander member in opposition to portions of the pharyngeal wall to be treated. The expander member is activated to urge the wall portions outwardly to an outwardly displaced position. The expander member is then deactivated while leaving the wall portions in the outwardly placed position and the expander member is removed from said airway. A further aspect of the treatment includes stabilization of at least a portion of the pharyngeal wall after compression of portions of the wall. | 0 |
BACKGROUND OF THE INVENTION
Field of the Invention
The present invention relates to a control system and control method for an oil well site and in particular to a system for providing automation and automatic wireless control of operations at a well site.
Description of the Prior Art
Management of elements used for drilling and pumping oil from well sites has historically been largely performed manually. The harsh conditions and hazards present special challenges for connecting and protecting control electronics. Moreover, areas around the well head require certain explosion proof rated components in many uses. Wiring, switches and other connections are subject to extremely harsh and often corrosive conditions and are subject to a higher failure rate. Moreover, control equipment is also subject to harsh operating conditions and also has a higher incidence of problems.
In addition, the information gathered relating to various parameters of drilling and connecting elements such as tubing or sucker rods has been limited for prior art systems. Even if such information exists, accessing and analyzing the information for modifying operations have also been limited.
It can be seen then that a new and improved control and data system for oil well sites is needed. Such a system should provide for wireless communication between various components to avoid the harsh conditions and possible damage to components and connections. Moreover, the components that are at the well site should be protected in enclosures and where necessary, in explosion proof enclosures. Such a system should also provide for collecting data and real time control and reporting of various conditions associated with the well site. The data should also be storable for further analysis at a later time and should also be accessible at remote locations. The present invention addresses these as well as other problems associated with controls at oil well sites.
SUMMARY OF THE INVENTION
The present invention is directed to a wireless and automatic control and data system for oil well site control and operations. The control system includes various subsystems disposed as modules in enclosures and where possible, placed remotely from a hazardous explosion zone surrounding the well head. Wireless communication through Bluetooth, Ethernet, cellular connections or other systems provides for communication and avoids damage to wiring and other components that conventional systems are prone to.
One control module is placed proximate the tong for the drill rig in a hazardous explosion zone. Explosion proof valves and control components are utilized and in communication with the tong and to control the tong. The various module elements may be enclosed in an explosion rated housing.
The first electronics module is located outside the hazardous explosion zone in a sealed enclosure and is connected to the tong control system module. The first electronics control module includes an Ethernet programmable controller and provides for wireless communication to other control modules.
A remote hydraulics module and a remote electronics module are spaced away from the well head at an opposite end of the drill rig. The two enclosures include wireless communication, such as Bluetooth and cellular connections. The remote electronics module is in communication with the first electronics module and includes additional controls, relays and processors. By positioning the modules away from the explosion zone, less protection is required at the remote location. The remote electronics module provides a cellular connection, radio or other wireless communication method for providing data and receiving instructions from a remote location. The remote electronics module acts as a central hub to coordinate control.
A human machine interface includes a screen suitable for use even in sunlight such as an industrial touch screen so that operations may be monitored at the well site and various data from pressure transducers, load sensors and flow sensors provide information on operations is displayed to operators. The human machine interface also includes a processor and may be connected to a further enclosure providing emergency stops and other switches. The interface is preferably mounted outside the hazardous zone but within sight of the well head and tong so that operators may observe operations while also monitoring the view screen.
The wireless technologies also provide for automation of the operations at the well site. The tong is controllable by processors in the electronics modules, actuating control valves and flow controls based on sensors, transducers and meters. Moreover, pressure transducers provide information regarding the stresses on the rig and provide alerts and alarms should problems be encountered. The present system also provides for acquiring data in multiple aspects of operations and provides for making real time adjustments. The information may be stored as well as being transmitted to remote locations or portable electronic devices. With such a system, improved operations are possible with operations automated as compared to conventional manually operated rigs. In addition to efficiency, safety and reliability are also improved as various components are removed from areas near the well head with control accomplished remotely.
These features of novelty and various other advantages that characterize the invention are pointed out with particularity in the claims annexed hereto and forming a part hereof. However, for a better understanding of the invention, its advantages, and the objects obtained by its use, reference should be made to the drawings that form a further part hereof, and to the accompanying descriptive matter, in which there is illustrated and described a preferred embodiment of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
Referring now to the drawings, wherein like reference letters and numerals indicate corresponding structure throughout the several views:
FIG. 1 is a diagrammatic view of a system for controlling well equipment according to the principles of the present invention;
FIG. 2 is a diagrammatic view showing the layout of the system of FIG. 1 ;
FIG. 3 is a flow diagram for operating the system shown in FIG. 1 ;
FIGS. 4A, 4B and 4C are diagrammatic views of a first housing for electronics for the system shown in FIG. 1 ;
FIGS. 5A, 5B, 5C, 5D and 5E are views of a second housing containing explosion rated components for the system shown in FIG. 1 ;
FIGS. 6A and 6B are diagrammatic views of a third housing containing hydraulic equipment for the system shown in FIG. 1 ;
FIG. 6C is an interior view of the third housing and the hydraulic equipment shown in FIGS. 6A and 6B ;
FIG. 6D is a detail view of the hydraulic equipment shown in FIG. 6C ;
FIG. 6E is a wiring diagram for controlling the hydraulic equipment shown in FIGS. 6A-6D ;
FIGS. 7A, 7B and 7C are diagrammatic views of a fourth housing for electronic equipment located remote from the hazardous explosion zone for the system shown in FIG. 1 ;
FIGS. 8A, 8B and 8C are diagrammatic views of a fifth housing containing interface equipment for the system shown in FIG. 1 ;
FIG. 9A is a perspective view of a first embodiment of a human machine interface utilized with the fifth housing;
FIG. 9B is a front view of a second embodiment of a human machine interface utilized with the fifth housing;
FIG. 10 is a side elevational view of a rig including the system shown in FIG. 1 ; and
FIG. 11 is a side elevational view of a trailer mounted system for the system shown in FIG. 1 configured for use with a rig.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring now to the drawings and in particular to FIGS. 1 and 2 , there is shown a control system 100 for acquiring and analyzing data to control equipment at a well site. The control system 100 includes multiple protected subsystems or modules. A tong hydraulics module 106 within the hazardous explosion zone 122 is protected in an explosion rated box 106 A. Other components are located remotely from the hazardous explosion zone 122 . The other control components are placed in enclosures to protect them from the elements and communicate via Bluetooth or other wireless communication. Therefore, problems associated with corrosion or other damage to wiring, relays and switches are eliminated. Moreover, the various components provide for automatic control of the tong 102 and automatic recording of operational data. The information is forwarded to a human machine interface 112 with a processor and may also be transmitted to remove locations for real time monitoring and automation of the various processes at the well site. It can be appreciated that the hydraulic enclosure for the tong 102 is within the hazardous explosion zone but the other subsystems or modules are removed from the zone, so that this equipment need only comply with lower hazard ratings and standards.
As shown in FIG. 10 , the system 100 is mounted to a conventional rig 120 in one embodiment. The rig 120 typically includes a frame or floor 124 serving as a base for all other components. Such a rig 120 includes wheels 128 for driving the rig to the well site. A cab 126 is typically at one end of the rig 120 while the mast or derrick 130 is raised at the opposite end. A hydraulic enclosure 108 A and electronics enclosure 110 A are mounted for example, on the front of the rig 120 . A main electronics module 104 may be hard wired to the tong hydraulic module 106 . The human machine interface 112 may have a screen and a keypad accessible within visual range of the well head and also includes an emergency stop box 114 A often mounted to the human machine interface 112 or within reach of an operator. The communication between the various subsystems are wireless except for the explosion rated hard wiring required for connection to the tong hydraulic module 106 in the explosion zone. Bluetooth Ethernet type communications 118 are provided between the components to eliminate hard wiring and associated drawbacks, but other wireless technologies could also be used. Moreover, an electronics module 110 may have equipment with a cellular connection for transmitting and receiving data, commands and other information to and from a remote control center at another location. Such a configuration provides for monitoring by owners, customers and others at locations remote from the well site and decreases the number of personnel required at the well site.
The control module 104 is typically mounted so as to be in direct electrical communication with the enclosed tong hydraulic module 106 and its various components. Referring to FIGS. 4A, 4B and 4C , the first electronics subsystem 104 includes a sealed cable 142 extending to the tong 102 and the components in the tong hydraulic enclosure 106 A. Moreover, an enclosure 104 A of module 104 houses a bidirectional Bluetooth communication system 146 , a relay bank 148 and one or more power supplies 150 . Moreover, also within the box is an Ethernet system 152 and a relay bank 148 . Pressure transducers 140 are positioned to sense various weights and fluid pressures associated with the well site operations. An Ethernet programmable controller such as may be available from Wago® Corporation is combined with the other components and provides for a system that can be controlled remotely and can also be programmed for automatic control of operations.
For some environments and/or applications the tong hydraulic enclosure 106 A is needed that is explosion rated.
The tong hydraulic module 106 connects to the tong 102 and supplies power to hydraulic motors and to actuate and stop the tong 102 . As shown in FIGS. 5A-5E , the tong hydraulic enclosure 106 A includes pneumatic actuators 158 as well as explosion proof valves 156 . The actuators 158 provide for operation of the tong within the hazardous explosion zone. The enclosure 106 A has an explosion proof housing that meets class 1 standards. Moreover, the actuators 158 and valves 156 are controlled and directly connected to the electronics module 104 , which is outside the hazardous explosion zone.
Referring to FIGS. 6A, 6B and 6C , the remote hydraulics subsystem 108 is located in the remote hydraulic enclosure 108 A. The remote hydraulic module 108 includes a flow meter 166 and a hydraulic flow controller for the tong 162 and a resistive thermal device (RTD). A flow meter 166 is also included in this system. A dump valve 168 and a valve bank 170 also direct and control hydraulic fluid flow. Pressure transducers 172 provide additional information on operating conditions and performance.
The remote hydraulics subsystem 108 is in the sealed enclosure 108 A next to or near the enclosure for the remote electronics module 110 . The remote electronics enclosure 110 A is shown in FIGS. 7A-7C . The module 110 acts as a central processor and is the central communication hub for the control system 100 . The remote electronics system 110 includes a Bluetooth transmitter receiver and a cellular modem. The system also includes a global positioning system 180 and one or more power supplies 182 . The remote electronics subsystem 110 also includes a relay bank 186 and one or more pressure transducers 188 . An Ethernet programmable controller 184 is connected to the other components. With such a configuration, the communication and control of the other components is automated and wireless. Moreover, data can be provided both to the human machine interface 112 as well as to a remote location for analysis and/or controlling remotely well site operations of the tong 102 and the rig 120 . Information can be provided in either direction and control inputs may be received to modify operations parameters.
An emergency stop module 114 shown in FIGS. 8A, 8B and 8C has a box 114 A mounting to or near the human machine interface 112 . The emergency stop enclosure includes explosion rated switches 198 and emergency stop 200 . Power supplies 202 provide power at different voltages to the module 114 . Ethernet 204 provides for communication with the remote electronics module 110 . The module also includes relays 206 and is in direct communication with the human machine interface 112 .
The human machine interface 112 , such as the model shown in FIG. 9A , may be an industrial rated computer touch screen or keyboard 212 in a frame 210 . The human machine interface 112 is preferably positioned so that it is outside the hazardous zone 122 while providing a view of the well head so an operator is able to view operations while monitoring the human machine interface 112 . The operating conditions and parameters may be monitored by an operator on the screen 212 and the operations may be modified by user input through the touch screen or other appropriate keyboard or controller.
In an alternate embodiment shown in FIG. 9B , the human machine interface 112 is mounted in a dedicated enclosure 112 A. In some embodiments the emergency stop module 114 is also housed in the enclosure 112 A. The human machine interface in the dedicated enclosure 112 A also includes a touch screen 212 and ports 214 for providing the human interface.
The use of Bluetooth and Ethernet communication systems as well as other connections provide for inputs and displays to the human machine interface 112 as well as to remote monitoring locations and for storage and memory. However, operators may also utilize portable electronic devices such as telephones, PDA's, tablets, laptops etc., to receive information and give commands.
As shown in FIG. 11 , for rigs that do not have the various control modules, but have a tong, a portable trailer 300 may be utilized to provide the various remote modules. The trailer 300 includes a frame 304 , a hitch 302 and wheels 306 . A remote control module compartment 308 includes the modules shown in FIG. 1 , except for the human machine interface. The communication to the tong may be direct with all other modules being remote and in communication with one another. This configuration also provides for safe operation as the trailer is positioned outside the hazardous zone 122 . Equipment storage 310 is also provided.
Referring now to FIG. 3 , a setup for the system is illustrated. To provide the automatic operation, inputs are made as to the type of rod or tubes being utilized including make, model, size or grade. The human machine interface 112 also provides for pulling up different screens for calibrating the various pieces of equipment prior to operation and for leading operators through equipment checks and diagnostics. Weights and other information from the pressure transducers may also be utilized to set initial conditions prior to operation. However, once all parameters have been input, the human machine interface 112 , which may include a processor loaded with appropriate software or connected to a controller with appropriate software in the remote electronics module 110 , is able to provide automatic control and operation of the tong and the rig at the well site. Moreover, information and modifications of the tong may be provided to and from remote locations or portable electronic devices. The present system 100 is also able to verify and certify the correctness of connections for tubing and/or rods and that the connecting equipment, such as the tong, is properly calibrated.
It is to be understood, however, that even though numerous characteristics and advantages of the present invention have been set forth in the foregoing description, together with details of the structure and function of the invention, the disclosure is illustrative only, and changes may be made in detail, especially in matters of shape, size and arrangement of parts within the principles of the invention to the full extent indicated by the broad general meaning of the terms in which the appended claims are expressed. | A control system for a well site, the well site includes connectable elements configured for inserting down a well. An explosion hazard zone surrounds the well site. A first electronics enclosure is remote from the explosion hazard zone and houses a first electronics module. A remote electronics control module is spaced apart from the first electronics housing and a remote hydraulics module removed from the first electronics module and the hazard zone module. The control system includes a human machine interface including a display and input. A central communications module is in wireless communication with the first electronics control module, the remote electronics module, and a remote location. A processor is in one or more of the first electronics module, the communications module or the human machine interface. | 4 |
BACKGROUND OF THE INVENTION
(1) Field of the Invention
This invention pertains to that portion of a railway vehicle underframe where the body bolsters are attached to the center sill and more particularly to the structure of the underframe to which the center plate is attached.
(2) Description of the Prior Art
The prior art center filler arrangements have provided a number of plates, weldments, rigidifying ribs and the like to adequately maintain the dimensional stability across the bottom of the center sill in order that the center plate may be attached to what is considered a completely flat surface. While the prior art has recognized the problem of uneven mating between the center plate and the bottom of the center filler as causing stress concentrations, cracking and premature failure, no satisfactory attachment arrangement has been provided.
SUMMARY OF THE INVENTION
This invention pertains to an improved center filler arrangement whereby a large center filler lug interconnects the side webs of a center sill in the bolster area. The center filler lug includes an enlarged piece of metal having recesses providing mounting surfaces for attachment of upwardly extending center filler plates horizontally extending bottom cover plates. By completely rigidifying the bottom portion of the center sill in the center filler area, dimensional stability is maintained between the side flanges of the center filler and an essentially flat surface can be provided for attachment of the center plate.
In operation and use, the center filler, comprising the lug and attached plates, may be constructed as a subassembly away from the railway vehicle and later positioned within the opening of the center sill in the bolster area. Afterwards, the bottom edges of the lug and the bottom plates are completely welded to the center sill. Thus the bottom of the lug and the side flanges of the center sill may be machined, if necessary, into a completely flat surface before the center plate is attached.
It is an object of this disclosure to provide improved center filler arrangement comprising a so-called center filler lug which is an enlarged piece of metal extending across the bottom of the center sill to produce a rigid box beam in the center filler area to resist tension, bending and other forces.
It is yet another object of the invention to provide a center filler having a bottom portion comprising a center filler lug positioned within the center sill opening and welded to each side of the center sill to provide a flat surface for attachment of a center plate.
These and other objects of the invention will become apparent to those having ordinary skill in the art with reference to the following description, drawings and appended claims.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective illustration of a portion of the underframe of a railway vehicle showing the structure at the junction of the bolster and center sill;
FIG. 2 is an exploded illustration of the center filler and a portion of the center sill into which it is positioned;
FIG. 3 is a transverse sectional view of the center filler disclosed herein;
FIG. 4 is a sectional view taken generally along lines 4--4 of FIG. 3;
FIG. 5 is a bottom view taken generally along lines 5--5 of FIG. 3; and,
FIG. 6 is a sectional view taken generally along lines 6--6 of FIG. 5.
DETAILED DESCRIPTION
Referring now to the drawings and in particular to FIG. 1, there is shown a railway center sill 10 which is a primary longitudinally extending load bearing member that extends from one end of a railway vehicle to another. The end portions of the center sill are frequently referred to as a draft sill and are designated in the drawings as item 12. Center sill 10 includes spaced, side webs 14 having bottom flanges 15 extending outwardly therefrom. As shown in FIG. 1, a so-called body bolster beam 16 extends from each side of the center sill and provides vertical support to the car body (not shown).
Attached to the underside of the car underframing at the junction of the bolsters 16 and the center sill 10 is a conventional center plate 18. Extending outwardly from the center plate portion 18 is a center plate skirt 20 which contains openings into which rivets or high strength bolts are extended to securely attach the center plate to the car underframe.
As shown in FIG. 2, there is a reinforcing structure above the center plate 18 that reinforces center sill 10 at the point where bolsters 16 are attached. This reinforcing structure is referred to as a center filler and designated by the number 24. Center filler 24 includes a front cover plate or rib 26 and a rear cover plate or rib 28. Extending horizontally and forming a portion of the center filler 24 are a front bottom cover plate 30 and a rear bottom cover plate 32. The bottom cover plate members 30, 32 of the center filler 24 are attached by welds at 27, 29 to a large center filler lug 34. Front and rear vertical ribs 26, 28 are attached to lug 34 by welds 23, 25 respectively. Ribs 26, 28 are also welded to the center sill webs 14. At each point of attachment of the plates lug 34 has been so contoured to not only provide a mounting surface or ridge for the attached plates but also to provide a recess for weld metal to securely form a connection between the center filler plates and the lug 34.
As mentioned earlier, if the center filler subassembly 24 is constructed away from the center sill 10 it is then inserted as a unit into the center sill opening and welded into position as shown by the welds indicated in FIGS. 3, 5 and 6. When so positioned the center filler lug 34 provides a rigid interconnection between the center sill side webs 14 and also performs a rigid continuation of the bottom flanges 15.
After the center filler lug 34 is positioned, the surface extending from the edges of the bottom flanges 15 and across the bottom surface of the lugs 34 may be machined into a completely flat surface to which the center plate mounting skirt 20 may be attached.
By utilizing a filler lug 34 approximately four inches thick and welding lug 34 securely in position, the interconnected portion of the center sill is rigidified to resist shear, tensile, twisting and fatigue loading. Further, bottom cover plates are approximately one inch thick and further rigidify and provide for even force distribution to reduce stress. The lug 34 is contemplated as being 3-5 times thicker than the bottom cover plate.
The foregoing description and drawings merely explain and illustrate the invention and the invention is not limited thereto, except insofar as the appended claims are so limited, as those who are skilled in the art and have the disclosure before them will be able to make modifications and variations therein without departing from the scope of the invention. | A center filler arrangement for railway vehicles provides a large center filler bottom lug welded in position and having mounting recesses for front and rear center filler plates to interconnect the side webs of a center sill to provide a rigid, dimensionally stable, flat surface for attachment of a center plate. | 1 |
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention generally relates to a semiconductor device including a transistor with a composite gate structure and a transistor with a single gate structure, and to a method for manufacturing such a semiconductor device. More specifically, the present invention relates to a nonvolatile semiconductor memory device including a nonvolatile memory cell having a composite gate structure of a floating gate and a control gate, and a transistor having a single gate structure of only a control gate, and also a method for manufacturing such a nonvolatile semiconductor memory device.
[0003] 2. Description of the Related Art
[0004] Among nonvolatile semiconductor memory devices in which information stored therein can not be erased even when power sources are turned OFF, the information can be electrically written into the respective memory cells of EPROMs (Electrically Programmable Read-Only Memories), whereas the information can be electrically written into the respective memory cells as well as can be electrically erased from each of these memory cells in EEPROMs (Electrically Erasable Programmable Read-Only Memories).
[0005] In general, as a memory cell for such an EPROM and an EEPROM, a MOS transistor with a composite gate structure is employed. The composite gate structure is constituted by stacking a floating gate electrode and a control gate electrode which are made of polycrystalline silicon films with an insulating film interposed therebetween. On the other hand, as a gate electrode of a single gate structure of another MOS transistor other than the memory cell transistor formed in, for example, a peripheral circuit region, two layers of polycrystalline silicon films, which are made simultaneously with forming of the floating gate and the control gate of the memory cell transistor, are utilized so that the steps in manufacturing of the transistor can be simplified. Such a semiconductor memory device structure is disclosed in, for instance, JP-A-59-74677, JP-A-7-183411, and JP-A-5-48046.
[0006] In JP-A-59-74677, the composite gate containing the floating gate and the control gate of the memory transistor, and the single gate structure of the peripheral transistor are both formed by three layers of a first polycrystalline silicon film, an insulating film, and a second polycrystalline silicon film, wherein in the peripheral transistor, the first polycrystalline silicon film is electrically connected via an opening fabricated in the insulating film to the second polycrystalline silicon film in an integral form, so as to provide a structure essentially identical to the gate of the single layer structure. However, the steps in manufacturing the memory device of JP-A-59-74677 would be complicated, since the opening must be formed at a preselected place of the insulating film located between the first polycrystalline silicon film and the second polycrystalline silicon film, which constitute the gate electrode of the peripheral transistor.
[0007] In JP-A-7-183411 and JP-A-5-48046, it is disclosed to form the floating gate and the control gate of a memory cell transistor by stacking successively the first polycrystalline silicon film, silicon oxide film and the second polycrystalline silicon film and to form the control gate of the peripheral transistor by stacking the second polycrystalline silicon film directly on the first polycrystalline silicon film. In such a case that the composite gate of the memory cell transistor and the gate electrode of the peripheral transistor are both formed of a lamination of the first and second polycrystalline silicon films, it is required to introduce an impurity such as phosphorous into the first and second polycrystalline silicon films thereby reducing the resistance of the films, since the films are also used as wiring layers. However, any of JP-A-7-183411 and JP-A-5-48046 describes nothing about this matter.
[0008] On the other hand, JP-A-2-3289 discloses a composite gate of the memory transistor which is manufactured by successively stacking a first polycrystalline silicon film into which phosphorous is doped at a low concentration, an interlayer insulating film, and a second polycrystalline silicon film into which phosphorous is doped at a high concentration.
[0009] Generally speaking, as a method for introducing an impurity such as phosphorous into the first and second polycrystalline silicon films constituting the floating gate and the control gate, there are an ion injection method in which accelerated impurity ions are injected into the polycrystalline silicon films and an vapor phase diffusion method or thermal diffusion method, in which oxyphosphorus chloride is vapored in a furnace, so that phosphorous is diffused from the vapor phase into the polycrystalline silicon films.
[0010] However, in the thermal diffusion method, since the impurity concentration is determined by the solid solution degree corresponding to the diffusion temperature, it is difficult to introduce the impurity at a low concentration into the polycrystalline silicon film. When the impurity concentration of the first polycrystalline silicon film of the memory cell transistor is increased, the boundary condition between the gate oxide film and the first polycrystalline silicon film is deteriorated, and the injection or extraction of electrons into or from the first polycrystalline silicon film of the floating gate can not be uniformly carried out, so that the memory cells fail to operate under stable condition.
[0011] On the other hand, in the ion injection method, it is difficult due to a breakage of the gate oxide film and/or occurrence of the crystal defects in the substrate to introduce the impurity into the first polycrystalline silicon film by an amount sufficient to lower its resistance. If the resistance of the first polycrystalline silicon film is not sufficiently lowered, then the resistance of the gate electrode made of the first and second polycrystalline silicon films of the peripheral transistor becomes higher. Then, if the resistance of the gate electrode becomes higher, the first polycrystalline silicon film is subjected to depletion state when the voltage is applied to the gate electrode, so that the threshold voltage of the peripheral transistor becomes unstable.
[0012] In a conventional nonvolatile semiconductor memory device in which both a memory cell transistor and another transistor other than the memory cell transistor have a two-layer polycrystalline silicon film gate structure, it is difficult to provide the polycrystalline silicon film of the under layer with an impurity concentration which satisfies the necessary condition of the memory cell transistor, as well as the condition required for the another transistor other than the memory cell transistor.
[0013] Further, the memory device of JP-A-59-74677 has a problem that since the first and second polycrystalline silicon films constituting the gate electrode disposed at an active region in the region for forming peripheral transistors are connected with each other through the opening formed at a predetermined position in the insulating film interposed therebetween, the impurities, if contained at a high concentration in the second polycrystalline silicon film, may be diffused into the first polycrystalline silicon film through the opening thereby deteriorating the boundary condition between the gate oxide film and the first polycrystalline silicon film.
SUMMARY OF THE INVENTION
[0014] An object of the present invention is to provide such a semiconductor device containing a first transistor having a composite gate structure, and a second transistor having a single gate structure. In this semiconductor device, each of the composite gate structure and the single gate structure is fabricated by a lamination of a first polycrystalline silicon film and a second polycrystalline silicon film. Also, an impurity concentration of the first polycrystalline silicon film for constructing the above-described composite gate structure, and an impurity concentration of the first polycrystalline silicon film for constituting the single gate structure can be controlled independently of each other.
[0015] According to one aspect of the present invention, a semiconductor device comprises: a first transistor having a composite gate structure containing a lamination of a first polycrystalline silicon film, an interlayer insulating film, and a second polycrystalline silicon film; and a second transistor having a single gate structure containing a lamination of a third polycrystalline silicon film and a fourth polycrystalline silicon film, wherein said first polycrystalline silicon film and said third polycrystalline silicon film have substantially the same thickness; said second polycrystalline silicon film and-said fourth polycrystalline silicon film have substantially the same thickness; said first polycrystalline silicon film and said third polycrystalline silicon film have different impurity concentrations controlled independently of each other; and said second polycrystalline silicon film, said fourth polycrystalline silicon film, and said third polycrystalline silicon film have substantially the same impurity concentration.
[0016] In a preferred embodiment of the present invention, the impurity concentration of said first polycrystalline silicon film is 1×10 18 to 10×10 19 atoms/cm 3 , and the impurity concentration of said third polycrystalline silicon film is 1×10 20 to 1×10 21 atoms/cm 3 .
[0017] According to another aspect of the present invention, a semiconductor-device comprises: a first transistor having a composite gate structure containing a lamination of a first conductive film, an insulating film, and a second conductive film; and a second transistor having a single gate structure containing a third conductive film; wherein said second conductive film and said third conductive film have substantially the same conductivity; said third conductive film has a thickness substantially the same as a total of a thickness of said first conductive film and a thickness of said second conductive film, or a total of a thickness of said first conductive film, a thickness of said insulating film, and a thickness of said second conductive film; and said first conductive film has a conductivity different from any one of a conductivity of said second conductive film and that of said third conductive film.
[0018] Furthermore, according to another aspect of the present invention, a semiconductor device comprises: a first transistor having a composite gate structure containing a lamination of a first conductive film, an insulating film formed on said first conductive film, and a second conductive film formed on said insulating film and having a conductivity different from that of said first conductive film; and a second transistor having a single gate structure containing a third conductive film having substantially the same conductivity as that of said second conductive film, and also having substantially the same thickness as a total of a film thickness of said first conductive film and a film thickness of said second conductive film, or a total of a thickness of said first conductive film, a thickness of said insulating film, and a thickness of said second conductive film.
[0019] According to one aspect of the present invention, a method for manufacturing a semiconductor device including a first transistor having a composite gate structure and a second transistor having a single gate structure, comprises the steps of: forming a first insulating film on a surface of a first region of a semiconductor substrate and forming a second insulating film on a surface of a second region of the semiconductor substrate; forming a first polycrystalline silicon film over an entire surface of said semiconductor substrate; introducing an impurity at a first predetermined concentration into said first polycrystalline silicon film by ion injection; patterning said first polycrystalline silicon film to a predetermined shape in said first region; forming a third insulating film containing at least a silicon nitride film on at least said first region except for said second region of said semi-conductor substrate; forming a second polycrystalline silicon film over an entire surface of said semiconductor substrate, introducing an impurity at a second predetermined concentration higher than said first concentration into said second polycrystalline silicon film by thermal-diffusion; patterning a lamination of said second polycrystalline silicon film, said third insulating film, and said first polycrystalline silicon film into a predetermined pattern in said first region to thereby fabricate said composite gate structure of said first transistor; and patterning a lamination of said first polycrystalline silicon film and said second polycrystalline silicon film into a predetermined pattern in said second region to thereby fabricate said single gate structure of said second transistor.
[0020] Moreover, according to another aspect of the present invention, a method for manufacturing a semiconductor device including a first transistor having a composite gate structure and a second transistor having a single gate structure, comprises the steps of: forming a first insulating film on a surface of an active region disposed in a first region of a semiconductor substrate and a second insulating film on a surface of an active region disposed in a second region of the substrate; forming a first conductive film over an entire surface of said semiconductor substrate; introducing an impurity at a first predetermined concentration into said first conductive film by ion-injection; forming a third insulating film above said first conductive film at an area including at least said first region except for said second region, or an area including at least said first region and said active region of said second region except for an element isolation region of said second region; forming a conductive film over the entire surface of said semiconductor substrate; introducing an impurity at a predetermined second concentration higher than said first concentration into said second conductive film by thermal diffusion; patterning a lamination of said second conductive film, said third insulating film, and said first conductive film into a predetermined pattern to thereby fabricate said composite gate structure of said first transistor in the active region of said first region; and patterning a lamination of said first conductive film and said second conductive film into a predetermined pattern to thereby fabricate said single gate structure of said second transistor in the active region of said second region.
BRIEF DESCRIPTION OF THE DRAWINGS
[0021] FIGS. 1A to 1 H are sectional views at the respective steps of a method for manufacturing a semiconductor device according to an embodiment of the present invention;
[0022] FIGS. 2A and 2B are sectional views of gate electrode portions of a memory cell transistor and a peripheral transistor in the semiconductor device of the present invention;
[0023] FIGS. 3A and 3B are a sectional view and a plan view, of a peripheral transistor in a semiconductor device manufactured by a method according to a second embodiment of the present invention; and
[0024] FIG. 4 shows a section of a peripheral transistor according to a third embodiment of the present invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0025] Referring now to FIGS. 1A through 1H , method for manufacturing an EEPROM (Electrically Erasable Read-Only Memory), according to a first embodiment of the present invention, will be described. In each of FIG. 1A to FIG. 1H , the left-sided portion represents a memory cell transistor formed in the memory cell region, whereas the right-sided portion shows a MOS transistor (peripheral transistor) fabricated in the peripheral circuit region.
[0026] First, to manufacture the EEPROM according to the first embodiment, as illustrated in FIG. 1A , a field oxide film 2 having a thickness of an order of 500 nm is formed on a surface of a silicon substrate 1 by the LOCOS method to provide an element isolation region. Then, a tunnel oxide film 3 having a thickness of an order of 10 to 12 nm is fabricated on the silicon substrate 1 at a memory cell region in an active region surrounded by the element isolation region made of the field oxide film 2 by way of the thermal oxidation method. Thereafter, a gate oxide film 4 having a thickness of an order of 10 to 40 nm is formed on the silicon substrate 1 at a peripheral circuit region in the active region surrounded by the field oxide film 2 by the thermal oxidation method. It should be noted that the tunnel oxide film 3 and the gate oxide film 4 may be formed in a reversed order or at the same time.
[0027] Next, as illustrated in FIG. 1B , a polycrystalline silicon film 5 having a substantially uniform thickness of an order of 150 nm is formed over the entire surface by the CVD method.
[0028] Subsequently, as indicated in FIG. 1C , phosphorus is introduced by the ion injection method into the polycrystalline silicon film 5 at an impurity concentration of an order of 1×10 18 to 1×10 19 atoms/cm 3 . It is undesired that the impurity concentration in the polycrystalline silicon film 5 exceeds the above impurity concentration, because the boundary condition between the tunnel oxide film 3 and the polycrystalline silicon film 5 in the memory cell region is deteriorated, so that electrons are no more uniformly injected into or extracted from the polycrystalline silicon film 5 serving as the floating gate. It should be noted that instead of phosphorous, arsenic ions may be injected.
[0029] Next, as shown in FIG. 10 , the polycrystalline silicon film 5 in the memory cell region is patterned to form a floating gate.
[0030] Thereafter, as indicated in FIG. 1E , an ONO film (silicon oxide film/silicon nitride film/silicon oxide film) 6 is formed over the entire surface by the CVD method. A thickness of each of the two silicon oxide film layers for constituting this ONO film 6 is in an order of 10 nm, a thickness of the silicon nitride film is in an order of 20 nm, and thus an overall thickness of the ONO film 6 , as converted to an equivalent thickness of the oxide film, is in an order of 30 nm.
[0031] Then, as shown in FIG. 1F , an etching treatment is carried out, while using a photoresist (not shown) of a pattern covering the memory cell region as a mask, so as to remove wholly a portion of the ONO film 6 formed on the peripheral circuit region.
[0032] Thereafter, as indicated in FIG. 1G , a poly-crystalline silicon film 7 having a uniform thickness of approximately 150 nm is fabricated over the entire surface by the CVD method.
[0033] Next, as illustrated in FIG. 1H , phosphorous is diffused into the polycrystalline silicon film 7 by way of the vapor phase diffusion method by performing the thermal treatment in a furnace in which oxyphosphorus chloride (POCl 3 : phosphoryl trichloride) is vapored. This phosphorous vapor phase diffusion is carried out until the impurity concentration of the polycrystalline silicon film 7 becomes an order of 1×10 20 to 1×10 21 atom/cm 3 so that the impurity concentration of the polycrystalline silicon film 7 becomes at least 10 times that of the polycrystalline silicon film 5 . It should be understood that instead of phosphorous, arsenic may be diffused.
[0034] At this time, since the polycrystalline silicon film 5 is in contact with the polycrystalline silicon film 7 in the peripheral circuit region, phosphorous is also diffused from the polycrystalline silicon film 7 into the polycrystalline silicon film 5 , so that the impurity concentration of the polycrystalline silicon film 5 becomes approximately 1×10 20 to 1×10 21 atoms/cm 3 . On the other hand, the ONO film 6 containing the silicon nitride film which has a low diffusion speed of phosphorous is interposed between the polycrystalline silicon films 5 and in the memory cell region. As a result, phosphorous does not diffuse through the ONO film 6 into the polycrystalline silicon film 5 in the memory cell region. Accordingly, the impurity concentration of the polycrystalline silicon film 5 in the memory cell region remains at an order of 1×10 18 to 1×10 19 atoms/cm 3 .
[0035] Subsequently, after photoresist (not shown) has been coated over the entire surface, this photoresist is patterned to a shape of a control gate 15 of the memory cell transistor 11 (see FIG. 2A ) in the memory cell region, and also a shape of a gate electrode 16 of a peripheral transistor 12 (see FIG. 2B ) in the peripheral circuit region. Then, by using the patterned photoresist as a mask, an anisotropic etching is carried out with respect to the polycrystalline silicon film 7 , the ONO film 6 , and the polycrystalline silicon film 5 . As a result, a floating gate made of the polycrystalline silicon film 5 , and a control gate made of the polycrystalline silicon film 7 are fabricated in the memory cell region, whereas a gate electrode of the peripheral transistor, which is made of the polycrystalline silicon films 5 and 7 , is formed in the peripheral circuit region.
[0036] Thereafter, a step of forming impurity diffusion layers (not shown) serving as sources and drains of the memory cell transistor 11 and the peripheral transistor 12 , by ion-injection using the control gate and the gate electrode as a mask, and further a step of forming an interlayer insulating film (not shown) which covers the overall areas of the memory cell transistor 11 and the peripheral transistor 12 are carried out to thereby accomplish the EEPROM.
[0037] As described above, in accordance with this first embodiment, phosphorous is introduced into the polycrystalline silicon film 5 at a relatively low concentration by way of the ion injection method and the ONO film 6 is left at least on the polycrystalline silicon film 5 of the memory cell region. Therefore, when phosphorous is introduced at a relatively high concentration into the polycrystalline silicon film 7 by way of the vapor phase diffusion method, the silicon nitride film of the ONO film 6 functions as a diffusion stopper of phosphorous. As a consequence, the impurity concentration of the polycrystalline silicon film 5 of the memory cell region can be maintained at a relatively low level, and further the impurity concentration of the polycrystalline silicon film 5 of the peripheral circuit region can be set to the relatively high level.
[0038] In this embodiment, the polycrystalline silicon films 5 , 7 forming the gate electrode of the peripheral transistor, and the polycrystalline silicon film 7 forming the control gate of the memory transistor have substantially the same conductivity which is higher than the conductivity of the polycrystalline silicon film 5 forming the floating gate of the memory transistor. Also, since the polycrystalline silicon films 5 and 7 have essentially uniform sectional areas, each of-the polycrystalline silicon films 5 , 7 forming the gate electrode of the peripheral transistor, and the polycrystalline silicon film 7 forming the control gate of the memory transistor have substantially the same resistance.
[0039] As a consequence, the boundary between the tunnel oxide film 3 of the memory cell transistor 11 and the polycrystalline silicon film 5 can be maintained at better condition, and furthermore, the resistance of the gate electrode of the peripheral transistor 12 can be made sufficiently low. As a result, it is possible to manufacture an EEPROM having high reliability and capable of operating at high speed.
[0040] It should also be noted that in this embodiment, the ONO film 6 formed in the peripheral circuit region is completely removed in the step of FIG. 1F . Alternatively, the ONO film 6 fabricated in the peripheral circuit region may be partially removed so as to retain its portion disposed at a region where the peripheral transistor is formed. Also, in this case, since phosphorous which has been introduced by the vapor phase diffusion method is diffused into the polycrystalline silicon film 5 through a portion where the ONO film 6 was removed, the impurity concentration of the polycrystalline silicon film 5 of the peripheral circuit region can be set to a relatively high concentration. Moreover, in this case, since the film structure of the memory cell transistor 11 in the longitudinal direction is substantially identical to the film structure of the peripheral transistor 12 in the longitudinal direction, the workability can be advantageously improved in the step of forming the floating gate by applying anisotropic etching to the polycrystalline silicon film 7 , the ONO film 6 and the polycrystalline silicon film 5 .
[0041] Also, in this embodiment, the description has been made of a case where an MOS transistor which is formed at the same time with the memory cell transistor 11 is the MOS transistor 12 of the peripheral circuit region. Alternatively, this embodiment may be applied to such a case that, for instance, the selecting transistor selectively switching the memory cell transistor 11 in the EEPROM is fabricated at the same time with the memory cell transistor 11 . Moreover, this embodiment may be applied not only to manufacturing of the EEPROM, but also any nonvolatile semiconductor memory device such as an EPROM in which each of the memory cell transistor and other transistors than the memory cell transistor uses a two-layer polycrystalline silicon film structure.
[0042] Next, a second embodiment of the present invention will be explained with reference to FIGS. 3A and 3B . FIG. 3A shows a section of a portion including the gate electrode of a peripheral transistor in a step of the method of manufacturing a semiconductor device according to the second embodiment of the present invention, i.e. a section along the line IIIA to IIIA′ in FIG. 3B , which is a plan view of the region including the peripheral transistor in the second embodiment.
[0043] In the second embodiment, substantially the same steps as those in the first embodiment as shown in FIGS. 1A to 1 E are carried out. The second embodiment is different from the first embodiment in the step of FIG. 1F . In the first embodiment, the ONO film disposed in the region where the peripheral transistor is formed has been removed in the step of FIG. 1F . On the other hand, in the second embodiment, only a part of the ONO film disposed in the element-isolation region where the field oxide film 2 is formed is removed, while unremoving a part of the ONO film disposed in the region 23 as shown in FIG. 3B including the active region 21 where the peripheral transistor is formed by masking the region 23 . Therefore, in the second embodiment, a part of the ONO film disposed on the first polycrystalline silicon film of the peripheral transistor and at an area substantially above the active region is unremoved in the step corresponding to FIG. 1F of the first embodiment. As a result, in the step of FIG. 1H where the impurity ions are introduced into the polycrystalline silicon film 7 , the impurity ions are not introduced into a portion 5 a ( FIG. 3B ) of the polycrystalline silicon film 5 disposed on the active region so that the impurity concentration of the portion 5 a remains at a low level and its resistance remains at a high level. However, a portion 5 b of the polycrystalline silicon film 5 disposed over the field oxide film 5 and serving as a wiring of the gate electrode has substantially the same impurity concentration as that of the polycrystalline silicon film 7 , resulting in a low resistance of the portion 5 b , which is effective to prevent the delay in operation of its circuit. Further, due to the same reason as that in the case of the tunnel oxide.
[0044] Incidentally, in FIG. 3B, 19 indicates the source/drain region of a peripheral transistor, 24 or 25 indicates a contact hole for connecting the source/drain region to a wiring layer (not shown) and 22 indicates a contact hole for connecting the gate electrode of the peripheral transistor to a wiring layer (not shown).
[0045] As previously described, according to the present invention, since the impurity is introduced at a relatively low concentration into the first polycrystalline silicon film by ion-implantation and also the insulating film containing the silicon nitride film is left on the polycrystalline silicon film in the memory cell region, when phosphorous is introduced at a relatively high concentration into the second polycrystalline silicon film by way of the thermal diffusion method, the silicon nitride film functions as a stopper for diffusion of the impurity. As a consequence, the impurity concentration of the first polycrystalline silicon film of the memory cell region can be maintained at a relatively low level, and further the impurity concentration of the first polycrystalline silicon film of the peripheral transistor can be set to a relatively high level.
[0046] As a result, the boundary between the tunnel oxide film (first insulating film) of the memory cell transistor formed in the memory cell region and the first polycrystalline silicon film can be maintained at better condition, and furthermore, the resistance of the gate electrode wiring of the MOS transistor formed in the peripheral region can be made sufficiently low. As a result, it is possible to manufacture a nonvolatile semiconductor memory device having high reliability and capable of operating at high speed. | A semiconductor device comprises a first transistor having a composite gate structure containing a lamination of a first polycrystalline silicon film, an interlayer insulating film, and a second polycrystalline silicon film; and a second transistor having a single gate structure containing a lamination of a third polycrystalline silicon film and a fourth polycrystalline silicon film, wherein the first polycrystalline silicon film and the third polycrystalline silicon film have substantially the same thickness; the first polycrystalline silicon film and the third polycrystalline silicon film have different impurity concentrations controlled independently of each other; the second polycrystalline silicon film and the fourth polycrystalline silicon film have substantially the same thickness, and the second polycrystalline silicon film, the fourth polycrystalline silicon film, and the third polycrystalline silicon film have substantially the same impurity concentration. Also, a method for manufacturing the above-described semiconductor device is described. | 7 |
FIELD OF THE INVENTION
[0001] The present invention is related to a hard key control panel for controlling a video/audio processing apparatus and a video processing system including the hard key control panel.
BACKGROUND
[0002] Live video productions such as TV productions are realized today using vision mixers. Vision mixers are commercially available e.g. from the companies Grass Valley, Sony, Snell, and Ross.
[0003] A vision mixer is a device used to select between different video input signals to generate a video output signal. Besides creating different kinds of transitions the vision mixer can generate a multitude of video effects and comprises keyers, matte generators, text generators etc. By means of the vision mixer the user also controls the routing of signals from various sources to selectable destinations.
[0004] The vision mixer also performs the routing and switching of audio signals accompanying the video signals. However, since the processing of video signals is more complex than the processing of audio signals the present patent application is focused on the video signal. It is to be understood that in the context of the present patent application the processing of the video signal also implies a corresponding processing of an accompanying audio signal. Only for the sake of better intelligibility of the description of embodiments of the present invention audio signals are not always mentioned in addition to the video signals.
[0005] In order to enable a multitude of functionalities, vision mixers consist of a huge amount of hardware components to process the video signals. The processing hardware components are located in one housing and are connected with local bus solutions in order to control all video processing hardware in real-time to meet the fast control requirements of live productions.
[0006] A conventional vision mixer comprises a central mixing electronic, several input channels and at least one output channel, a control unit and a user interface. Such kind of vision mixer is described for example in DE 103 36 214 A1.
[0007] Live video productions like news, sports and stage events are produced in fixed or mobile TV studios. Conventionally, a TV studio is equipped with a vision mixer, multi-viewer and monitor walls, storage systems and digital video effects devices, external crossbars and the like. All these devices consist of a big amount of dedicated hardware stages, external cabling and specific configurations settings reflecting the internal and external hardware structure and connectivity. The entire TV live production is controlled by operating a control unit controlling the devices. For historical and architectural reasons the operation and configurations of the control interface for these devices is hardware oriented. For this reason the operator of the TV live production has to keep simultaneously in mind two completely different views on a TV production, namely the sequence of the scenes of the TV production on the one hand and the hardware operations required for obtaining the desired workflow of the scenes. These two different views on the same live TV production have nothing to do with each other. Therefore, the task of operating a live TV production is complicated. But it is made even more complicated due to the fact that the operator can influence almost all hardware components. Consequently, there is a significant risk to execute mal-functions such as losing an input signal which is required for a scene which is currently on-air. At the same time, the operator cannot access all functionalities needed for the workflow of the scenes without setting certain delegation levels.
[0008] Existing operating interfaces for conventional TV live production systems are inflexible because they are tied to the underlying hardware of the devices used for a TV production. This makes them also very complicated and their operation is frequently counter intuitive. As such TV live productions are error prone unless special efforts are made to support the operator.
SUMMARY OF THE INVENTION
[0009] Obviously there is a need for improving the operating interface for live TV productions. Therefore, the present invention suggests a hardware control panel enabling the user, typically the director of a live TV show, in a manner which reflects the flow of the different scenes in the live production. Specifically, the present invention suggests a hard key control panel.
[0010] The control panel according to the invention comprises a plurality of hard key control elements which are arranged in different groups. A first group of control elements is assigned to select a predefined scene for being broadcasted. A second group of control elements is assigned to select signals for a currently broadcasted scene being composed of several input signals including camera signals. A third group of control elements is assigned to select signals for a next scene which is selectable for being broadcasted by operating a control element of the first group. The control panel of the present invention enables the production director to control a live video production in an intuitive way.
[0011] Advantageously, the hardware control panel provides an operating interface that matches with the workflow of TV productions. It enables context related direct access to all functionalities which are needed during the TV show. However, it does not provide direct access to those functionalities which are not needed in a specific scene. Hence, it significantly reduces or even prevents malfunctions during a TV production.
[0012] According to an embodiment of the present invention the panel comprises a fourth group of control elements assigned to scenes and signals remaining in stand-by for future use. The signals include camera signals.
[0013] Advantageously each group of control elements is illuminated in a different colour to indicate to which group they pertain and their different functionality to the user. In this case the control elements can be illuminated pushbuttons enabling illumination in different colours.
[0014] In an embodiment of the invention the control panel is communicatively connected with a graphical user interface to control functions assigned to the control panel.
[0015] According to an embodiment the control panel is communicatively connected with a graphical user interface and a pointing device. A pointer associated with the pointing device is controllable by means of the pointing device to be either displayed as graphical element in the graphical user interface or as highlighted hard key element on the control panel. This embodiment enables to control the control panel in the same way as the graphical user interface by means of the pointing device. In this case it is particularly advantageous to enable the pointing device to control functionalities assigned to the highlighted hard key element. This provides for additional flexibility of the control panel. The hard key element can be a hard key control element or a display.
[0016] According to a variant of the control panel the pointing device is a computer mouse movable on a mouse pad. The computer mouse is effective to display a graphic element on the graphical user interface when the mouse is situated in a first area on the mouse pad. The computer mouse is effective to highlight a button on the control panel if the computer mouse is situated in a second area of the mouse pad. The same computer mouse enables influencing the graphical user interface and the control panel. It has been found to useful if the hard key element is highlighted by at least one of a distinctive colour, a distinctive icon, a distinctive shape, a distinctive text size, and a distinctive text font.
[0017] In a further embodiment of the invention the control panel is communicatively connected with a graphical user interface to assign the control elements of the control panel to the different groups. This feature increases the flexibility of the control panel and it can be adapted to the needs for a specific live production.
[0018] In an advantageous embodiment the first group of control elements comprises a dedicated control element which puts a signal prepared in the fourth group on-air or into the status of a next on-air signal.
[0019] It has been found useful if each group of control elements is associated with a dedicated display. In this case it is advantageous if the dedicated display is adapted for being illuminated in different colours.
[0020] In an embodiment of the invention the control element(s) are hard key button(s). More specifically, the buttons can be illuminated pushbuttons enabling illumination in different colours to further increase the usability of the control panel.
[0021] According to another aspect the invention relates to a video processing system. According to an embodiment, the video processing system includes at least one video processing unit and a control panel for controlling the at least one video processing unit.
DRAWINGS
[0022] In the drawing an embodiment of the present invention is illustrated. Features which are the same in the figures are labeled with the same or a similar reference numbers. It shows:
[0023] FIG. 1 a schematic block diagram of a system for video processing which is operated by a method according to the present invention;
[0024] FIG. 2 a schematic layout of the control panel according to the present invention;
[0025] FIGS. 3 and 4 are enlarged portions of the control panel shown in FIG. 2 ;
[0026] FIG. 5 the control panel connected with a graphical user interface;
[0027] FIG. 6 is a schematic diagram illustrating the workflow of a TV production utilizing the present invention;
[0028] FIGS. 7A and 7B a portion of FIG. 6 ; and
[0029] FIGS. 8A and 8B another portion of FIG. 6 .
DETAILED DESCRIPTION
[0030] FIG. 1 shows a schematic block diagram of the architecture of an alternative system for processing video and/or audio signals which has been described in detail in the European patent application EP12175474.1 filed by the same applicant. The proposed architecture of the inventive system allows building the hardware platform on standardized IT technology components such as servers, graphical processing units (GPU) and high-speed data links. Typically, these standardized IT components are less costly than dedicated broadcast equipment components. Besides the cost advantage the proposed system benefits automatically from technological progress in the area of the above-mentioned IT components. In the proposed system video processing hardware is split into smaller and flexible video processing units and combines dedicated control, video and audio interconnections into one logical data link between the individual processing units. The data links are designed such that they have a reliable and constant time relation. The data links are typically based on a reliable bidirectional high-speed data connection such as LAN or WAN. The individual processing units work independently as fast as possible to achieve or even exceed real-time processing behavior. Normally, real-time processing means that the processing is finished until the next video frame arrives. Therefore, the term “real-time” is a relative term and depends on the video frame rate. The system ensures that overall production real-time behavior with simultaneous processing is achieved and generates a consistent production signal PGM-OUT. This general concept is described in greater detail in the following.
[0031] In the video processing system shown in FIG. 1 , the video processing hardware is organized in processing units 101 , 103 , 105 , and 107 according to the geographical distribution of a production i.e. according to the geographical distribution of the resources enabling the production as it is shown schematically in FIG. 1 . The technical core of each processing unit is a server, one or several graphics processing units (GPUs) and high-speed data links operated by a processing application framework and dedicated algorithms. The processing application framework and the algorithms are realized in software. The algorithms are adaptable and extendable to also realize further functionalities going beyond the functionalities of conventional vision mixers. The video signals are processed by GPUs in commercially available graphic cards. Hence, conventional video processing by dedicated hardware is replaced by software running on standardized IT components. All the processing capabilities of the GPUs are available and enable new video effects.
[0032] The operator controls the whole production as if it was at one single production site in a single production unit next to the control room. The entire production process is moved from dedicated video/audio and control routing to common data links. The individual wiring hardware such as SDI connections is replaced by standardized data networks. The routing of all signals in the data networks is bidirectional and the production output and monitoring signals like dedicated multi-view outputs can be routed to any production unit which is connected in the network without extra cabling expenses.
[0033] High-speed data networks are more and more available not only in video production sites such as film or TV studios but also in wide area distribution networks, e.g. multiple of 10 G Ethernet or Infiniband.
[0034] In studios, professional video networking means that the video content is transferred uncompressed. For HDTV formats 1080i/720p data rates of 1.5 Gbit/s are resulting in studio environment where uncompressed audio and video data are used. For HD format 1080p a net data rate of even 3.0 Gbit/s results.
[0035] Referring back to FIG. 1 every block represents one of the distributed processing units belonging to the system which is referred to in its entirety with reference number 100 . In the exemplary embodiment shown in FIG. 1 processing unit 101 is located in a football stadium in Frankfurt. Processing unit 101 receives as local sources 102 camera signals from the stadium, slow-motion video from a local slow-motion server and eventually audio and video signals from an interview taking place locally. Processing unit 103 is also located in Frankfurt but not necessarily in the same place as processing unit 101 . Processing unit 103 receives camera signals as local sources 104 from a live presenter in an interview room. Processing unit 105 is located in Berlin and represents the main processing room providing additional processing power for the ongoing production as well as access to archives and servers where for example advertisement clips are stored. The archives and the servers are indicated as local sources 106 . The local sources 102 , 104 , and 106 provide the video and/or audio signals as SDI or streaming data. Finally, there is a processing unit 107 which represents the live control unit (LCU) located in Munich from where the live production is controlled and monitored. The production result is leaving processing units 103 and 105 as video and audio output signals PGM-OUT 108 and 109 for being broadcasted. The processing units 101 , 103 , 105 , and 107 are interconnected with each other with reliable bidirectional high-speed data links 110 as shown in FIG. 1 . The data links 110 enable communication between the processing units 101 , 103 , 105 , and 107 and provide constant and known signal delays between the production units. It is noted that the high-speed data links 110 represent logical data links which are independent of a specific hardware realization. For example, the data links 110 can be realized with a set of several cables. In the situation shown in FIG. 1 the data links 110 are an Internet protocol (IP) wide area network (WAN). In a WAN special measures have to be taken to make sure that the data packages are received in the same sequence as they have been sent over the network to meet the requirements of video processing. Appropriate measures can be taken on the protocol and/or hardware level of the network such that the system behaves like a single big vision mixer.
[0036] The present invention suggests a hard key panel concept which supports the production director in the LCU (live control unit) 107 in Munich to control and monitor the TV production. The inventive control panel relieves the production director to a large extent of hardware operations and allows him focusing more on the workflow which will be explained in further detail below.
[0037] TV productions like news, sports, stage shows contain a lot of stories having a well-defined unique appearance of the specific production. E.g. a news production always follows the same structure though it may vary from broadcaster to broadcaster. Typically, there is an opening by the moderator, contributions about national and international politics, and the weather forecast. These parts of the news production are called “stories” comprising several scenes. There may be 5 to 100 stories in a show or news production and there are 5 to 10 scene templates which define the appearance of the production. The production director uses the scene templates and fills them with the story composed of several scenes, e. g. the moderator presents his opening. A filled scene template is an executable scene for the TV production.
[0038] Taking these scene templates and filling it with the story finally provides executable scenes for the news production. Sequencing executable scenes and controlling dedicated scene transitions is finally under the control of the live production director.
[0039] Transferring this concept from a live video production into the area of a graphical slide presentation may help to illustrate the new concept of the present invention even better. The slide presentation of the quarterly report of a company corresponds to the video production of a news production. Like a news production the quarterly report always follows the same structure namely the course of business in the last year, the evolution of headcount, income and spending and finally it provides an outlook into the next year. The templates for the slides are fixed and do not change. However, the content of the slides changes and reflects the evolution of the company from one reporting period to the next one. The creator of such a presentation does not prepare the slides each time from scratch but rather uses the predefined templates and fills them with updated contents to generate an “executable slide” for the presentation. The presenter controls when the next content is shown within one template and when the next template is called up.
[0040] In the context of the present patent application a scene is a predefined composition of video layers in front of a video background. A scene is used to tell the viewer a portion of a story in the way the director has conceived it. Typically, the evolution of the story is a sequence of scenes. While a story evolves, audio and video sources used in a scene can change; the scene can change its layout, size and appearance; video layers can be added or removed. All this is under the control of the production director. If a new story begins within a TV production, normally a new scene is executed.
[0041] The present invention builds on this general concept and suggests a hard key control panel supporting TV production directors to operate real-time TV productions. A key point of the present invention is to suggest a hard key control panel enabling mapping of the described scene oriented operating philosophy onto a hard key control panel.
[0042] FIG. 2 shows a top view on an embodiment of the hard key control panel 201 according to the present invention. The elements of the hard key control panel 201 , or briefly control panel, are arranged in a plurality of blocks having a matrix type structure with columns and rows. The columns are labeled with letters D, C, B, A, X from left to right and the rows are labeled 1 , 2 , and 3 from bottom to top. The blocks in the different matrix rows are assigned with different functionalities and, therefore, matrix row 1 is also called story level 1 , matrix row 2 is called on-air level 2 , and matrix row 3 is called next scene level 3 . The functionalities of the levels 1 , 2 , and 3 will be described in greater detail further below.
[0043] The different blocks of the control panel 201 will be described by making reference to the column and row where the block is located in the matrix shown in FIG. 2 . The blocks having a similar functionality will be described together.
[0044] The blocks are identified according to the following convention: Block A on level 1 is identified as 1 -A. Several blocks on several levels in the same column are identified by the relevant level numbers separated by a comma and the letter identifying the row where the blocks are located, e.g. 1 , 2 , 3 -A. Similarly, several blocks in several rows on a single level are identified with the level number where the blocks are located and the letters identifying the relevant rows separated by a comma, e.g. 1 -A,B.
[0045] Blocks 1 , 2 , 3 -X are used to make transitions between two signals either manually controlled with an effect lever 202 or automatically executed. The automatic execution is initiated when the operator pushes a button “Auto” 203 . A default button “Def” 204 allows the operator to select which kind of transition (horizontal or vertical fade, swirl effect, etc.) is used as a default. By operating buttons “In” and “Out” 205 , 206 the operator selects the transition for the entry into a new story and for the exit from a current story. Frequently, the transition into a new story and out of the current story is different and part of the “look and feel” of a specific TV production. The functionalities of the blocks 2 -X and 3 -X are in principle the same as of the block 1 -X though on different levels of the live production.
[0046] In the area of columns A to D of the control panel 201 each block is composed of eight pushbuttons 211 and an associated display 212 . As an example block 2 -C is framed with a dashed line in FIG. 2 . However, it is noted that the layout of the control panel 201 shown in FIG. 2 is only an example and the present invention is not limited to a particular layout. E.g. in another embodiment of the control panel 201 , each of the before mentioned blocks comprises three rows of buttons 211 and one associated display 212 . Also, the control panel 201 is configurable that each block has less or more than four buttons in a row following the format of the live production. In FIG. 2 the block 219 having six buttons in rows 213 , 214 is indicated with a dotted line. However, for the sake of simplicity the following description shall be based on the principle layout shown in FIG. 2 (two rows of four buttons, one display) without limiting the scope of the present invention.
[0047] In blocks 1 -A,B there are two rows of pushbuttons 211 and the associated display 212 . For the sake of clarity each row of buttons 211 in the control panel is labeled with reference numbers from 213 to 218 . Row 213 of buttons 211 of blocks 1 -A,B puts a signal on-air when the attributed button is activated. For this reason row 213 in blocks 1 -A,B is also called the “program row”. In the situation shown in FIG. 2 the signal associated with button 211 1 is currently on-air. If another button in row 213 is pushed then the signal associated with this other button is put on-air which means it is immediately broadcasted.
[0048] With buttons 211 in row 214 of blocks 1 -A,B the next story to be put on-air is selected. Therefore, row 214 in blocks 1 -A,B is called the “preset row”. When the operator or editor selects a scene by activating an associated button 211 VII , then the scene is displayed on a monitor 615 ( FIG. 6 ) and can be checked and verified by the operator as it will be explained in greater detail with reference to FIGS. 6 and 7 . The selection of the signal in the preset row 214 has further consequences, namely, the selected source signals from cameras, hard disc recorders etc. are made available and are locked for other users like a coeditor 607 ( FIG. 6 ). E.g. the camera man is informed by a yellow tally light that his camera has been selected for the next scene and it is going on-air soon. The signals from cameras are live signals.
[0049] The buttons 211 of the control panel 201 are illuminated in different colors, also called “tally colors” or “tally lights”, to inform the user about their functionality. The tally lights have the advantage that the operator can immediately recognize the underlying functionality of the specific button without having to read an alphanumeric display. For formal reasons the different tally colors of the buttons are symbolized by different patterns in FIG. 2 . E.g. the button 211 I in program row 213 is illuminated in dark red colour to indicate the on-air signal. Likewise the effect lever 202 is illuminated in red color (indicated by a dark vertical bar versus a light vertical bar in effect levers 202 on levels 2 and 3 ) for the same reason.
[0050] FIG. 3 shows an enlarged view of blocks 1 -A,B,X in which also the labels of the displays 212 are visible. The displays 212 in blocks 1 -A,B show from right to left seven stories forming the live video production. The stories are labeled “Opener”, “Mission1”, “LocNews” for local news, “Movie”, “Finance”, “StkXChg” for stock exchange, and “Election”. Each of the seven stories is linked with specific scene template which is used for the story. It is to be noted that display sections are illuminated with a tally light too but this cannot be shown in FIG. 3 .
[0051] The composition of the scene which is currently on-air is controlled in block 2 -A (block 2 -B remains idle) which is shown in greater detail in FIG. 4 . The story “Mission1” is currently on-air. The story has an opener which shows the moderator in a first setting. Button 211 II in row 216 is activated ( FIG. 4 ). Then the wrap-up is provided by a reporter and button 211 III is activated. During the wrap-up the name of the reporter, here “Brian C”, is inserted by activating button 211 IV . It follows an interview by activating button 211 V and the name of the interviewed person is inserted temporarily by activating button 211 VI . Finally, at the end of the story “Mission1” the moderator makes some closing remarks. For this purpose the operator activates again button 211 II . Hence, the story “Mission1” is composed of several scenes which use predefined scene templates and input signals including camera signals which are live signals. As mentioned before, the production director controls the evolution of the story simply by activating the buttons 211 .
[0052] After the story “Mission1” is finished, the operator starts the next story “LocNews” the first scene of which is already prepared in block 3 -A,B ( FIGS. 2 and 4 ) which is indicated by the darker green tally light of button 211 vII ( FIG. 4 ). The operator puts the story “LocNews” on-air by simply activating the button 211 vIII . At this moment the tally light of button 211 vIII turns from light red into dark red. At the same time the current setting of blocks 3 -A,B replaces the setting of blocks 2 -A,B and a new next scene (“Movie”) is prepared in blocks 3 -A,B by pushing button 211 IX ( FIG. 3 ). The transition by pushing the button 211 vIII is a hard cut from “Mission1” to “LocNews”. However, the editor or operator can execute the transition also by moving the effect lever 202 or by activating the auto button 203 on level 1 . The latter initiates an automatic transition.
[0053] In this way, the production director controls the live TV production in an intuitive way and can completely focus on the story without being bothered by directly operating hardware components. Another advantage is that the production director is prevented from making malfunctions because he directs the story within predefined scene templates which by default cannot be changed during the live production.
[0054] In some types of productions like a news production following a script, normally each story with its associated scenes is shown only once. Therefore, in an embodiment of the present invention the story assignment displayed on the displays 212 in blocks 1 -A,B is shifted one by one from left to right each time a story is terminated.
[0055] The blocks 1 -A,B; 2 -A,B; and 3 -A,B are connected with multi-viewers providing a complete overview of the input signals and the resulting output signals after processing. It is noted that the output signals which are only displayed on a multi-viewer are not necessarily calculated in full resolution by the processing unit 107 to save processing power. Only the on-air signals have to be calculated by the processing unit 107 in full broadcast quality. The processing unit 107 is taken only as an example and the same applies of course to any other processing unit in the audio and video processing system.
[0056] Blocks 1 , 2 , 3 -C,D ( FIG. 2 ) are a working area which is used to support a live video production by preparing and verifying scenes to be put on-air. The use of the different parts of the control panel 201 will be explained in further detail with reference to FIGS. 6 to 8 . The blocks 1 , 2 , 3 -C,D are also connected to a multi-viewer.
[0057] The different functionalities of the different blocks of the control panel 201 shown in FIG. 2 are described in connection with a specific position of the respective blocks in the control panel. However, it is to be noted that advantageously the control panel 201 is adaptable so that a certain functionality of a specific block is assignable to any block in the control panel since the physical structure of each block is the same, namely eight buttons 211 and one display 212 .
[0058] FIG. 5 shows a graphical user interface (GUI) 501 displayed on a monitor 502 . The graphical user interface 501 is communicatively connected with the control panel 201 . The graphical user interface 501 enables the operator to control functionalities 501 of the video processing by means of a pointing device such as a mouse 503 shown in FIG. 5 . The position of the mouse 503 on a mouse pad 504 corresponds to the position of the graphical pointer 505 displayed on the monitor 502 as it is known from conventional computer applications. When the operator moves the mouse 503 in an area 506 indicated with a dotted line on the mouse pad 504 , the pointer 505 moves on the monitor 502 in the area where the graphical user interface 501 is displayed. However, when the operator moves the mouse 503 beyond the area of 506 into area 507 indicated with a dashed line on the mouse pad 504 , then the pointer 505 disappears on the monitor 502 and a button 508 on the control panel 201 is highlighted. The highlight is for example an increased illumination level of the button 508 or its illumination in a different color. The position of the button 508 corresponds to the position of the mouse 503 in the area 507 on the mouse pad 504 . The transition of the pointer 505 from the graphical user interface 501 to become a highlighted button 508 on the control panel 201 is comparable with the commonly known transition of a cursor from a first monitor to a second monitor when both monitors are connected with the same computer.
[0059] In the same way as it is described with reference to the highlighted button 508 also a display on the control panel 201 can be highlighted. The highlighting is achieved by the distinctive color, icon, text size or text font.
[0060] The movement of the mouse 503 on the mouse pad 504 is illustrated with an arrow 509 . The corresponding movement of the pointer 505 across the graphical user interface 501 and its transition into the highlighted button 508 on the control panel 201 is symbolized by an arrow 510 . In this setup the operator can execute various kinds of commands with left and right mouse clicks, turning a mouse wheel etc. including drag and drop functions. By using the functionalities provided by the mouse 503 the operator can also adapt the functionalities of the control panel 201 by changing the underlying software of the control panel. E.g. the graphical user interface 501 comprises widgets allowing the operator of the system to reassign functionalities of the blocks of the control panel 201 . In consequence, the functionalities of the hard key control panel 201 are adaptable in a similar way as a graphical user interface. In FIG. 5 the mouse 503 is only shown as an example for all kinds of other pointing devices such as a trackball, graphics tablet, joystick, keyboard etc.
[0061] In another embodiment of the present invention also the physical layout is different. In this embodiment which is not shown in the drawing, the rows C and D are arranged on the right side of column X, such that the sequence of the columns is B, A, X, C, D when using the denomination of the columns defined in FIG. 2 . In yet another embodiment of the present invention the control panel 201 shown in FIG. 2 is composed of two separate hardware devices. The first device comprises columns B, A, and X and the second device comprises columns C, D. The two devices are connectable such that in response to the need of the operator the second device can be connected to the left or to the right side of the first device. In the first alternative the sequence of the columns is D, C, B, A, X and in the second alternative the sequence of the columns is B, A, X, D, C. In further embodiments of the invention more than two such hardware devices are used in the live production as it is shown with the reference to FIG. 6 and described further below.
[0062] FIG. 6 illustrates in a symbolic way the production process including the people involved and their interactions with the production equipment, in particular with the control panel 201 . The production director 601 (or briefly: director) directs the production by issuing director instructions including “production start” 602 and “story change” 603 . During the course of the production the director 601 can take an “emergency action” 604 to respond to an unforeseen incident like the sudden end of a conference, the arrival of a politician or a movie star, a foul in a football match etc. Finally, the director terminates the production by issuing a “production end” instruction 605 . The instructions of the director 601 are executed by a live editor 606 and a co-editor 607 who control the control panel 201 which is symbolized in FIG. 6 only by its matrix structure. The responsibility of the live editor 606 mainly is to control the on-air story 608 and the next on-air story 609 . The live editor executes his task by operating the columns A, B, and X of the control panel 201 . If the workload determined by the dynamics of the video production permits, the live editor 606 may also take care of Far1 Story 610 . However, this is not always possible during live productions. This is the reason why the co-editor 607 is present as well who mainly is responsible to prepare the Far1 Story 610 and a Far2 Story 611 . Far1 and Far2 stories 610 and 611 are both still in preparation for going on-air at a later point in time. For preparing the Far1 Story 610 and the Far2 Story 611 the co-editor 607 controls columns C and D of the control panel 201 . The co-editor 607 works on his own control panel 201 ′ which is set up such that it includes only two times columns C and D because the co-editor 607 has no responsibility for the on-air story 608 and the next on-air story 609 controlled by the live editor 606 by means of columns A, B, and X of the control panel 201 . The Far1 Story 610 as well as the Far2 Story 611 can replace the next on-air story 609 or the on-air story 608 . This is illustrated by arrows 612 and 613 , respectively. Thus, the arrows 612 and 613 indicate a preset and change queuing of the production. Director 601 , live editor 606 and co-editor 607 can monitor the signals of the on-air story 608 , next on-air story 609 , Far1 Story 610 , and Far2 Story 611 on associated multi-viewer monitors 614 to 617 , respectively. The multi-viewer monitors 614 to 617 permit not only monitoring in real time the selection of signals, which may include live signals, but also the live composition of the scenes with their dynamic changes and effects that are applied. It is noted that there can be more than two stories in preparation or only one. Far1 story 610 and Far2 story 611 are used only as illustrative example. Similarly, it is not fixed which person works on the preparation of the Far1 and Far2 story. The invention is completely flexible in this regard.
[0063] The work of the live editor 606 related to the on-air story 608 is illustrated in greater detail in FIG. 7A . In a first step 701 the live editor 606 activates the next on-air or Far1 or Far2 Story for going on-air. The live editor then controls the story which is on-air by selecting scenes and activities in step 702 . He continues to do so until the on-air story reaches its end which triggers in step 703 the decision of the live editor 606 to continue to control the on-air story by returning to step 702 or to activate the next story for going on-air by returning to step 701 . If an unforeseen incident requires immediate reaction there is a request for an immediate story change in step 704 . In response to the request in step 704 a story which is available for going on-air is activated in step 705 .
[0064] The preparation of the next on-air story 609 by the live editor 606 is shown in FIG. 7B . It only requires to select the story in step 706 and to verify in step 707 the scenes and presets of the story.
[0065] As mentioned before the live editor 606 may have sufficient time to prepare the Far1 Story. However, the working process for preparing the Far1 Story 610 will be described only in connection with the work of the co-editor 607 which is illustrated in connection with FIGS. 8A and 8B . The necessary steps for preparing the Far1 Story are the same for the live editor 606 and for the co-editor 607 .
[0066] FIG. 8A illustrates in a flow diagram the steps for preparing the Far1 Story 610 . In a first step 801 the co-editor 607 selects the story for update or verification. An update may be necessary if the situation has changed during the course of the live production e.g. a politician has started to give interviews after a conference. Then, the co-editor 607 verifies and prepares the scenes and presets of the Far1 story in step 802 . In step 803 he decides if the story is ready for going on air or not. If it is not ready for going on air the co-editor 607 continues with step 802 . If the story is ready for going on air it is shifted into the block 3 -A ( FIGS. 2 and 4 ) of the next on-air story as soon as the current next on-air story actually went on-air.
[0067] Depending on the video production and the available resources the co-editor 607 is enabled to prepare a Far2 Story 611 . The working process is the same as for preparing the Far1 Story 610 and is shown in FIG. 8B .
[0068] During the course of the video production the currently on-air story 608 is replaced at a certain point in time by the next on-air story. At the same time one of the prepared stories 610 or 611 becomes the next on-air story. In this way the live editor 606 and co-editor 607 can sequentially prepare and control the live video production.
[0000]
List of reference numbers
100
processing system
101
processing unit
102
external sources
103
processing unit
104
external sources
105
processing unit
106
local sources
107
processing unit
108, 109
output signals
110
data links
201
control panel
202
effect lever
203
Auto button
204
default button
205
in button
206
out button
211
push button
212
associated display
213-218
rows of buttons
219
block
501
graphical user
interface
502
monitor
503
mouse
504
mousepad
505
graphical pointer
506, 507
areas on the
mousepad
508
button
509, 510
arrow
601
production director
602
production start
603
story change
604
emergency action
605
production and
606
live editor
607
co-editor
608
on air story
609
next on air story
610
Far1 Story
611
Far2 Story
612, 613
arrows
614 to 617
multi-viewer
monitor
701 to 707
process steps
801 to 803
process steps
801′ to 803′
process steps | A control panel comprising a plurality of hard key buttons which are arranged in different groups is suggested. A first group of buttons is assigned to select predefined scene settings. A second group of buttons is assigned to select signals for a currently broadcasted scene. A third group of buttons is assigned to select signals for a next scene which is selectable by operating a button of the first group. The hardware control panel provides an operating interface that matches with the workflow of TV productions. It enables context related direct access to all functionalities which are needed during the TV show. However, it does not provide access to those functionalities which are not needed in a specific scene. Hence, it significantly reduces or even prevents malfunctions during a TV production. | 7 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The invention relates generally to exercise equipment. More particularly, the present invention relates to a compact, simple and flexible full body exercise apparatus.
2. Background and Objects of the Invention
There are many types of exercise equipment known in the art. One class of exercise equipment available is intended to work specific muscle groups. For example stationary bicycles, treadmills, and stepper machines, are generally employed to work the leg and buttock muscles. Often these devices are large and not easy to store. Further, if a full body workout is desired, wherein most or all muscle groups are exercised, other apparatus must be employed.
There are also known in the art many complex exercisers. These are often configurable or adjustable to enable a user to do many varied and different exercises, typically in a number of positions (i.e., sitting, laying down, standing, etc.). For example U.S. Pat. No. 4,821,152 to Wolff, is one such apparatus. These systems are mechanically complicated, having many parts, and may require the user to rearrange or add constituent portions, to accommodate the various exercises supported. These types of exercisers are also expensive, and typically do not fold to enable a user to store them in a small area, for example, under a bed.
Objects of the present invention are, therefore, to provide a new and improved exercise apparatus having one or more of the following capabilities, features, advantages, and/or characteristics:
a modular simple device;
enables a user to exercise many of the muscles or muscle groups of the user's body;
low cost construction using many readily available components and or materials;
storable in a relatively small area;
quickly adjustable to accommodate users of differing heights.
The above listed objects, advantages, and associated novel features of the present invention, as well as others, will become more clear from the description and figures provided herein. Attention is called to the fact, however, that the drawings are illustrative only. Variations are contemplated as being part of the invention, limited only by the scope of the appended claims.
SUMMARY OF THE INVENTION
In accordance with the invention, an exercise apparatus of the type for exercising particular muscles or muscle groups of a user is disclosed, wherein muscles are exercised by providing resistance to repetitive movements of the user. A horizontally extending frame assembly is provided having at least two biasing elements, which may be provided by helical springs or other known elastic means. Each biasing element has a first end and a second end, with the first end adjustably fixed to the frame assembly. A plurality of foot pedals are included that are slidably mounted on the frame assembly. The foot pedals are moveable between a first position, proximate to the user, and a second distal position. The second end of each biasing element is coupled to each foot pedal for biasing the foot pedals in the first position and providing resistance when the user applies a suitable force to move a respective foot pedal to the second position. A seat is provided that is adjustably mounted to the frame assembly. The position of the seat may be altered to enable the distance between the seat and foot pedals to be adjusted to a user desired distance.
The exercise apparatus further includes a plurality of elastic cables, each having a first end and a second end. The first end of the elastic cables is removably anchored to the frame assembly, with the second end configured for grasping by the user. In a preferred embodiment, a suitable means may be provided for anchoring the first end of each of the elastic cables to the frame assembly in one of a plurality of available and preconfigured positions. The foot pedals and elastic cables are each configured to enable the user to exercise particular muscles or muscle groups, as desired.
BRIEF DESCRIPTION OF THE DRAWINGS
In the drawings, like elements are depicted by like reference numerals. The drawings are not necessarily to scale, with the emphasis instead placed upon the principles of the present invention. The drawings are briefly described as follows:
FIG. 1 provides a perspective view of the exercise apparatus of the present invention.
FIG. 2 is an exploded view of a portion of a frame assembly included with the invention.
FIG. 3 illustrates a linear rod assembly employed with the exercise apparatus.
FIG. 4 depicts a biasing element in the form of a helical biasing spring that may be employed with the linear rod assembly.
FIG. 5 is a perspective view of an embodiment of a seat arrangement employed with the invention.
LIST OF REFERENCE NUMERALS USED IN THE DRAWINGS
10--exercise apparatus
12--frame assembly
16--slotted members
16a--slots
18--cross members
18a--thru holes
20--foot pedals
20a--first position (biased, proximal position)
20b--second position (distal position)
22--seat
22a--seat back
24--seat support member
24a--locking pin
28--adjustment knob
30--cross supports
32--biasing element
32a--first end (of biasing element)
32b--second end (of biasing element)
32--biasing element
36--elastic cable
36a--first end (of elastic cable)
36b--second end (of elastic cable)
38--handle
40--linear rod assembly
42--threaded rod
42a--front end (of the threaded rod)
42b--back end (of the threaded rod)
42c--threaded portion (of the threaded rod)
42d--unthreaded portion (of the threaded rod)
44--first end block
46--second end block
50--slider
52--threaded block
56--rod
58--linear roller bearing
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring now to FIG. 1, there is provided a perspective view of the exercise apparatus 10 of the present invention. A frame assembly 12 is comprises a pair of spaced and elongated slotted members 16 and a pair of cross members 18. As illustrated in FIG. 1, the slotted members 16 and cross members 18 are connected to establish a substantially rectangular shape to the frame assembly 10. The slots 16a in each of the slotted members 16 are provided to enable foot pedals 20 that are included with the exercise apparatus 10 to be slidably mounted to the frame assembly. The foot pedals 20 are slideable to be movable between a first position 20a and a second position 20b. The first position 20a may be termed `proximal` to the user, while the second position 20b may be termed `distal` to the user (or the position/location of the user). The foot pedals 20 are each biased in the first position 20a by a biasing element 32. As best seen in FIGS. 3 and 4, the biasing element 32 is depicted as a spring, but may be provided by other suitable means having a desired elasticity. The biasing elements 32 may also be termed an elastic means. A seat 22 is adjustably mounted on the frame assembly 10 to enable the position of the seat to be adjusted to in a `forward and back` manner. Accordingly, the position of the seat may be adjusted to accommodate user's of differing heights. In particular, if a user has long legs the seat may be moved back, thereby increasing the distance between the foot pedals 20 and the seat 22. Means may be provided, such as in the form of a spring loaded locking pin 24a, to secure the seat in the final desired position. Alternately, a clamping or friction based device may be employed to lock the seat in a selected position. A plurality of seat support members 24 may be included to slide on the slotted members 16 to facilitate the adjustment of the seat 22.
As can be seen in FIG. 1, a plurality of elastic cables 36 are included with the exercise apparatus 10, each having a first end 36a and a second end 36b. The first end 36a of the elastic cables 36 may be removably anchored or mounted to the frame assembly 12 to enable the user to select a particular location during an exercise session. The particular means utilized to anchor the first end 36a to the frame assembly 20 may simply be a wing nut and stud (not shown) or other known `quick connect` mechanisms available in the art. The position where the elastic cables 36 are anchored is contemplated to be at or near the corners of the frame assembly 12 (as shown). Each elastic cable 36 may be configured with a handle 38, fixed to the second end 36b of the elastic cable.
Turning to FIG. 2, there is illustrated an exploded view of a portion of the frame assembly 12. Clearly shown are the spaced elongated slotted members 16 and the cross members 18. One of the cross members may be configured with thru holes 18a, to accommodate the adjustment knobs 28. One or more cross supports 30 may be included (as seen in FIGS. 1 and 2) to stiffen the frame assembly 12, as required. It must be understood that the frame assembly 12 may be provided by other structures as can be provided by skilled persons. For example, each cross member 18 and each slotted member 16 may be comprised of a plurality of elements or components (not explicitly shown for simplicity).
Referring now to FIG. 3, there is illustrated a linear rod assembly 40 employed with the exercise apparatus 10. A threaded rod 42 is provided having a to a front end 40a and a back end 40b. The threaded rod 42 includes threaded portions 42d, and may include un-threaded portions 42c. A first end block 44 is rotatably mounted at the front end 40a, while a second end block 46 is rotatably mounted at the back end 40b. The first end block 44 and the second end block 46 are each provided to rotatably support the threaded rod 42 within the frame assembly 12.
As skilled individuals will appreciate, a bearing means (not shown) may be employed to rotatably mount the first end block and the second end block to the threaded rod 42 to reduce the friction encountered by a user when rotating the threaded rod. A threaded block 52 is adjustably mounted on the threaded rod 42 so as to enable the (linear) position of the threaded block 52 to be altered or adjusted with respect to the front end 40a and the back end 40b. The treaded block is arranged to receive and secure the first end 32a of a respective biasing element 32. The position of the threaded block 52 on the threaded rod 42 is alterable by the user by rotating the threaded rod 42 via the adjustment knob 28. A slider 50 is also included and slidably disposed upon the threaded rod 42, possibly on the unthreaded portion thereof. The slider 50 is movable between a first position 20a and a second position 20b. The slider 50 is configured to accept and securely hold a respective foot pedal 20. Note that the first position 20a of the slider 50 corresponds to the first position of the foot pedal, and the second position 20b of the slider 50 corresponds to the second position of the foot pedal 20.
As can be seen in FIG. 3, the second end 32b of the biasing element 32 is secured to the slider 50. Therefore, the second end 32b is coupled to the foot pedal 28. Accordingly, by rotating the threaded rod 42 (via the adjustment knob 28), the distance between the threaded block and the slider may be altered by the user to adjust the tension or biasing force applied to a foot pedal 20 by the biasing element 32.
It is important to note that the adjusting knobs 28 may be arranged to be provided at the front ends 42a of the linear rod assembly 40 instead of the back end. Further, it is contemplated that adjustment knobs may be provided at both the front end and the read end of each linear rod assembly 40.
Referring now to FIG. 5, a rod 56 can be seen that may be mounted on the seat support members 24, which may be grasped by the user to aid the balance of the user when using the exercise apparatus 10. The rod 56 would be arranged to have a length that is greater than the width of the seat 22. Also shown in FIG. 5 are linear roller bearings 58, that may be included to reduce the friction encountered by the user when adjusting the position of the seat 22.
It is important to understand that the above description of the exercise apparatus 10 of the present invention is exemplary only, and other equivalent arrangements may be provided. Therefore, while there have been described the currently preferred embodiments of the present invention, those skilled in the art will recognize that other and further modifications may be made without departing from the present invention, and it is intended to claim all modifications and variations as fall within the scope of the invention. | An exercise apparatus of the type for exercising the muscles of a user by providing spring or elastic loaded resistance to repetitive movements of a user having a horizontally extending frame assembly. The exercise apparatus includes biased foot pedals and elastic cables that are user operable to exercise a variety of muscles or muscle groups of a user. An adjustable seat having a back that may be folded for storage is also included. | 0 |
BACKGROUND OF THE INVENTION
This invention relates to multiwell apparatus for biological and biochemical analyses.
Microwell test plates, inclusive of the so-called microtiter test plates, have been adapted for a wide range of biological and biochemical laboratory procedures. Most of such apparatus currently in use has been standardized to enable use in conjunction with a standard 96 well microtiter plate having a 12 by 8 array of microwells.
Multiwell trays characterized as "microfiltration trays" are disclosed by U.S. Pat. No. 3,319,792 issued to Leder et al, U.S. Pat. No. 3,730,352 issued to Cohen et al, U.S. Pat. No. 3,888,770 issued to Avital et al, U.S. Pat. No. 3,963,615 issued to Plakas, U.S. Pat. No. 4,167,875 issued to Meakin, U.S. Pat. No. 4,317,726 issued to Shepel, U.S. Pat. No. 4,427,415 issued to Cleveland, U.S. Pat. No. 4,526,690 issued to Kiovsky et al and UK 1,490,362. Similar plates, specifically intended for cell culture are disclosed by U.S. Pat. No. 4,304,865 issued to O'Brien et al, U.S. Pat. No. 4,483,925 issued to Noack and PCT publication W086/07606. Seiler-et al - U.S. Pat. No. 4,079,009 and Kremer - U.S. Pat. No. 3,928,203 disclose similar microwell plates adapted for use in microchromatography. Likewise, numerous different designs for microwell plates intended for use in immunodiffusion techniques have been patented, e.g. Saravis - U.S. Pat. No. 3,378,347 and Goldsmith - U.S. Pat. No. 3,390,962. U.S. Pat. No. 4,090,850 issued to Chen et al and U.S. Pat. No. 4,246,339 issued to Cole et al disclose multiwell plates specifically designed for immunoassays. All such apparatus disclosed by the prior art includes at least one plate member having an array of wells closed at the bottom with a porous or microporous filter member or membrane. The terminology "microfiltration apparatus" and "multiwell filtration plate" as used herein is intended to embrace all such types of apparatus, regardless of the nature of the permeable medium at the bottom of the individual test wells.
Only a few of the prior art designs for microfiltration apparatus provide for separate collection of the filtrate emanating from the individual wells. With most of the prior art apparatus, attempts to separately collect the filtrate from each well would be unsuccessful or suffer from unreliable results due to cross-contamination between the wells by wicking, capillary action, spilling, running, etc. Further, with many of the prior art designs the apparatus must be used with a separate capital vacuum manifold which is expensive and represents a considerable investment. This is particularly limiting in applications such as genetic research where it is desirable to use numerous microfiltration plates simultaneously. Also, the use of a separate capital manifold limits the ability to stack more than one microfiltration plate in applications requiring serial passage of fluid through more than one plate. An additional problem with much of the prior art microwell apparatus is that little or no provision is made for sanitary handling of the residual materials at the completion of the test. This is a particularly acute problem in assays of bodily fluids containing potentially contagious viral strains and in the case of radiography test procedures where it becomes necessary to handle residual materials and apparatus contaminated by radioactivity.
SUMMARY OF THE INVENTION
Accordingly, it is an object of the present invention to provide a multiwell filtration apparatus which can be adapted for use in any or all of the aforementioned techniques, particularly immunoassays, nucleic acid probe assays, radiography assays, microchromatography and microculture of cell suspensions and tissue.
It is another object of the present invention to provide such an apparatus which is "disposable."
Yet another object of the present invention is to provide a multiwell microfiltration apparatus having its own self-contained vacuum manifold, thus dispensing with the need for capital investment in a separate piece of vacuum manifold apparatus and allowing stacking or serial use of multiple multiwell filtration plates.
Yet another object of the present invention is to provide an microfiltration multiwell plate with provision for separate collection of the filtrate from each test well into respective wells of a conventional microtiter or other plate.
Still another object of the present invention is to provide a novel method for the sanitary handling of filter media or membrane containing or holding a residue resulting from the test procedure.
Still another object of the present invention is to provide such an apparatus having the capability for a quantitative recovery of liquid medium from each test well.
Yet another object of the present invention is to provide such an apparatus and method particularly adapted for radiography techniques.
Still another object of the present invention is to provide such an apparatus and method particularly adapted for microchromatography.
Yet another object of the present invention is to provide such an apparatus and method particularly adapted for the microculture of cell suspensions and/or tissue.
These and other objects and features of the invention will become apparent to those skilled in the art from a reading of the detailed description to follow, in conjunction with the drawings and appended claims.
In order to provide for separate collection of filtrate from each well of an array of test wells, without cross contamination therebetween, the present invention provides a manifold plate having an array of filtering wells, each of the wells being closed at its bottom by a planar bottom member providing a filter support surface. A discharge nozzle or passageway depends from each well bottom (planar bottom member) in a direction normal thereto, with one such discharge nozzle or port being provided in fluid communication with each filtering well. Each of these filtrate nozzles or drain ports extends from the lower surface of the planar bottom member to such an extent that it will enter into the well of a conventional multiwell, e.g. microtiter, plate in alignment therewith and mate with the sidewall of the aligned well of the multiwell plate. In this manner, the filtrate can be delivered to the collection well of the multiwell plate as a steady stream, in the manner one would use a pipette, rather than dropwise. The ability to quantitatively collect filtrate into a receiving multiwell plate provides options for improved immunoassays, nucleic acid probe assays and other test procedures.
In one embodiment the planar bottom members are integral with the manifold plate, the whole being molded as a single piece. In a second embodiment a separately formed filter support plate closes the bottoms of the test wells, thus providing a planar bottom member for each filtering well, the filter support plate being sealed to the manifold plate around the bottom of each filtering well.
In a preferred embodiment, the aforementioned microfiltration apparatus has the filtrate discharge nozzle or port provided in a skirt which is adapted to mate with the interior cylindrical surface of a well of a conventional microtiter plate. In the preferred embodiment the skirt is a segmented skirt, i.e. it is in the form of two pair of diametrically opposed pins, with one of the four pins serving as the filtrate discharge nozzle for a given filtering well.
In another of its aspects, the apparatus of the present invention has novel features which enable a uniquely different approach to the handling of contaminated filter media. Toward this end, the aforementioned skirt is adapted to function as an alignment guide in conjunction with a punch. Thus the skirt, preferably segmented to avoid airlock, circumscribes an area aligned with the axis of a given well in the manifold plate, which circumscribed area is equal in diameter to or slightly smaller than the bottom of the well. The skirt is tapered inwardly toward its axis to receive and guide a punch into axial alignment with the filtering well. Thus, after completion of filtration, the plate may be inverted and a punch is received in the skirt and driven through the bottom of the planar bottom member and the filter medium disposed thereon. The cut bottom of the planar bottom member thus serves as a sanitary punch, shearing the filter medium, with the well itself functioning as a cutting die. The blanks cut from the well bottoms and corresponding blanks cut from the filter medium may be received onto a radiography film or into any collection device appropriate to the particular test procedure for which the apparatus is used. Preferably, each punch is one of a linear array of eight punches which are used in sequence along a given row of eight filtering wells. After the last well of a given row has been punched through, the linear array of punches is moved forward to the next row and the process is repeated, without risk of contamination or carryover by the punches.
In another of its aspects, the present invention provides a disposable microfiltration assembly which includes its own disposable vacuum manifold. Toward this end, a manifold plate is provided with parallel, spaced inner and outer peripheral skirts depending from its upper planar surface. The outermost skirt serves to align the apparatus with and mate with a conventional multiwell plate. Preferably, this outer- most skirt is of such a length that when the manifold plate assembly is placed on a planar surface, no well bottom or filtrate discharge nozzle will touch that planar surface. In other words, the manifold plate assembly of the present invention may be placed on top of a laboratory bench without fear of contamination. The innermost skirt is designed to engage and seal with the upper planar surface of a collection plate, which may be either a conventional microtiter plate, another manifold plate, or an open tray for receiving wash fluids. In order to seal the innermost skirt to the collection plate, the free end of the innermost skirt may be provided with a downwardly opening peripheral channel and an elastomeric gasket contained therein or a separately molded elastomeric gasket may be inserted between the innermost and outermost skirt, which gasket has an inner beaded lip which extends under the innermost skirt. The length of this innermost skirt is such as to maintain a small clearance between the bottom surface of the filter support plate and the top planar surface of the collection plate and vacuum communication between this clearance space and the interior of the manifold plate may be provided in any suitable manner, for example by provision of apertures extending through the filter support plate. A vacuum port is provided which extends laterally through both skirts into the interior of the manifold plate. Thus, a conventional petcock or a fitting associated therewith may be inserted into the vacuum port and the space surrounding the exteriors of the filtering wells can be thereby evacuated to draw filtrate through the filter discharge nozzles.
The present invention also provides for several novel handlings of otherwise conventional radiography techniques. For example, a manifold plate may be placed on top of x-ray film in a black box or cassette after the test reagents have been added to the respective filtering wells, whereby the x-ray film is developed. In another radiography method in accordance with the present invention, the filtered residue to be analyzed by radiography is collected in the well bottoms of a manifold plate in accordance with the present invention and then that assembly is inverted and an area of the bottom of each well is punched through onto an x-ray film placed below same in a dark room or dark box whereby the filter medium with radioactive residue to be analyzed comes into direct contact with the x-ray film.
The present invention also provides a novel cell culturing method employing the apparatus described above. The cells are cultured in the wells of one manifold plate (culture plate), with a second manifold plate, as described above, mounted on top of the culture plate with the array of filtering wells of the top manifold plate aligned with the wells of the culture plate and separated therefrom by a semipermeable membrane in the bottom of each filtering well of the top manifold plate. Nutrient solution added to the uppermost filtering well array is "sterilized" by passage through the semipermeable membrane. Each well in the culture plate is fed nutrient containing solution through the semipermeable membrane and through a filtrate discharge nozzle as described above. When desired, culture medium is similarly harvested from the culture plate containing the growing cells by placing the culture plate, with the manifold plate on top of it, on top of a collection plate and applying a vacuum to the port of the culture plate.
BRIEF DESCRIPTION OF THE DRAWINGS
In the drawings:
FIG. 1 is a top plan view of one embodiment of a manifold plate of the microfiltration apparatus of the invention;
FIG. 2 is a right side elevational view of the manifold plate of FIG. 1, in cross-section, taken along A--A in FIG. 1;
FIG. 3 is a top plan view of a filter support plate which mates with the bottom of the manifold plate of FIGS. 1 and 2;
FIG. 4 is a right side elevational view, in cross section along B--B in FIG. 3;
FIG. 5 is a bottom plan view of the filter support plate depicted in FIGS. 3 and 4;
FIG. 6 is a partial side elevational view, in cross section, showing the manifold plate as depicted in FIG. 2 and the filter support plate as depicted in FIG. 4 assembled together with a conventional filter medium and a conventional microtiter plate;
FIG. 7 is a view similar to that of FIG. 6 but showing an alternative embodiment for a seal between a manifold plate and a collection plate or a second manifold plate;
FIG. 8 is a top plan view of one well of the filter support plate of FIG. 3;
FIG. 9 is a partial side elevational view of the manifold plate and filter support plate of FIG. 6 inverted to receive a punch;
FIG. 10 is a view similar to that of FIG. 6 but showing an alternative embodiment wherein the manifold plate and filter support plate have been modified to provide a press fit therebetween;
FIG. 11 is a perspective view of an alternative embodiment wherein the filter support surfaces and well bottoms are integrally molded with the manifold plate as a single piece;
FIG. 12 is a perspective view of the manifold plate of FIGS. 1 and 2 and the filter plate of FIGS. 3-6 clipped together with a conventional microtiter plate;
FIG. 13 is a side elevational view of a "C"-clip depicted in FIG. 12;
FIG. 14 is a perspective view of a punch as used in the present invention;
FIG. 15 is a side elevational view, in cross-section, of an assembly for culturing cell suspensions or tissues in accordance with the present invention;
FIG. 16 is a side elevational view of a manifold/filter support plate assembly adapted for radiography in accordance with the present invention;
FIG. 17 is a side elevational view of a manifold/filter support plate assembly adapted for another radiography method in accordance with the present invention; and
FIG. 18 is a fragmented side elevational view, in cross-section, of a manifold plate/filter plate assembly adapted for a method of microchromatography in accordance with the present invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIGS. 1-10 illustrate embodiments of the present invention wherein a single filter support plate 26 forms the bottoms of all wells of a manifold plate 10.
FIGS. 1 and 2 show a manifold plate 10 which constitutes one element of a complete embodiment of the microfiltration apparatus of the present invention. As is illustrated in FIG. 1, the manifold plate 10 has an upper planar surface 12 and an array of wells 14 depending therefrom. The array in the illustrated embodiment consists of 96 wells in an 8 horizontal row (A-H) and 12 vertical row (1-12) arrangement. Such a 96 well array has become a standard in the industry for microtiter plates in general. As seen in the cross-sectional view of FIG. 2, each well 14 is formed with a bore 16 and a counterbore 18. The transition between bore 16 and counterbore 18 is preferably a smooth "S"-shaped surface 17. Each well 14 terminates in a male fitting 20 which is received in a mating depression 32 in the upper surface of a filter support plate 26 (see FIG. 6) as described below.
A second element of this first-described embodiment of the present invention, the filter support plate 26, is illustrated in FIGS. 3-5. As seen in FIG. 3, the filter support plate 26 has a top planar surface 30 having a plurality of depressions 32 equal in number to and alignable with wells 14. The sidewall of each depression 32 is slightly tapered and is of such a size as to mate with male fittings 20 of the manifold plate 10 as shown in FIG. 6. Thus, the manifold plate 10 and the filter support plate 26 are assembled by aligning the two together with a male fitting 20 above each depression 32. A circumferential weld between the mating surfaces of depression 32 and male fitting 20 is formed for each well 14 in a conventional manner, for example by shear joint ultrasonic welding. These welds, extending around the circumference of the bottom of each well 14 are also hermetic.
Thus, the bottom 34 of each depression 32 closes the bottom of a well 14. A circular piece of filter medium is placed in the bottom of each well 14 flush against surface 34. As is further shown in FIG. 3 each well bottom (filter support surface) 34 has a channel 38 extending across its surface to collect filtrate passing through the filter medium. The filtrate passes through channel 38 and into an aperature 40. As seen in FIG. 4, 40 opens into a filtrate discharge passage 42 which extends through pin member 44. Pin 44 is one of four pins, shown as 44, 45, 46 and 47, symmetrically arranged around an axis alignable with a well 14. These pins 44, 45, 46 and 47 together form what is referred to herein as a segmented skirt. The spacing of these pins 44, 45, 46 and 47 is such that they mate with the inside surface of a well of a microtiter plate (or another manifold plate) and thereby assist in establishing and maintaining alignment. The gaps between the pins allow air to escape from the filtrate collection wells in the microtiter plate and thus prevent airlock and the potential for cross-contamination between wells by capillary action, etc. In embodiments not employing the punch feature, described in detail below, only a single pin, i.e. that provided with a filtrate discharge nozzle 42 is necessary. However, in embodiments employing the punch feature at least two and preferably at least three pins are provided.
As is further seen in FIGS. 4 and 5 the pins 44, 45, 46 and 47 circumscribe an area 48 which is coaxial with the depression 32. It can also be seen that 48 itself is indented from the lower planar surface of the filter support plate 26 so that the filter support plate between surfaces 34 and 48 is substantially thinner than the thickness of the plate elsewhere. This thinness of the filter support plate at the bottom of each well 14 plays an important part in the utilization of the apparatus of the present invention as will be explained below. The diamond shaped areas 55 (FIG. 5) are substantially thinner than surrounding areas 53.
The location of these pins relative to the axis of the area circumscribed thereby (the wall axis) i.e. the radial distance between a given pin and that axis, is important because it is designed to have each pin contact the inner cylindrical wall of a well of a microtiter plate placed in alignment therewith. As noted above, such an arrangement assists in alignment of the filter support plate with a microtiter plate (or another manifold plate). It also provides for a quantitative transfer of liquid volume from a test well 14 to a collection well of a microtiter plate. In accordance with the present invention the pin 44 which carries the filtrate passage 42 engages the sidewall of a collection well so that the filtrate emanates from pin 44 as a steady stream, rather than drop by drop. The tip of pin 44 extends below the lip of the collection well, e.g. suitably 1-2 mm below the lip. Thus, pin 44 functions in the manner a properly used pipette would function to deliver liquid. In other words, instead of a drop adhering to the tip of a nozzle centered within the well, in accordance with the present invention, the liquid which would otherwise form such an adhering drop flows smoothly down the sidewall of a collection well and a maximum volumetric transfer of liquid from each well 14 into a collection well is thereby attained. The area 48 circumscribed by the pins is coaxial with and substantially equal in diameter to the bore 16.
As seen in FIGS. 2 and 6, the manifold plate 10 has an outer peripheral skirt 22 which performs two distinct functions. Firstly, the outer skirt 22 serves to align the manifold plate 10 (and filter support plate 26) with a conventional microtiter plate (or second manifold plate) and secures the microtiter plate (or second manifold plate) in alignment therewith. Secondly, skirt 22 is of such a length that with the filter support plate 26 in place, the manifold plate 10 may be placed on a laboratory bench or on any planar surface without any portion of the filter support plate contacting that surface. Thus, the microfiltration apparatus of the present invention may be handled rather freely within a lab without fear of contamination by whatever might be present on the counter or benchtop constituting the work station.
Spaced inboard from the outer peripheral skirt 22 is a second or inner peripheral skirt 24 which is shorter than skirt 22. Skirt 24 also serves two purposes. Firstly, it is of such a length that there will be a suitable clearance between the lower surface of the filter support plate 26 and the top surface of a microtiter plate or other collection tray to allow for a vacuum to be established within the microtiter plate for the purpose of drawing filtrate through the filter support plate by vacuum. As can be seen in FIG. 6, the filter support plate 26 is of such a size that it can be fit within the inner skirt 24. In fitting together the manifold plate 10 and the filter support plate 26, the terminus of each well 14, i.e. male fitting 20, is received in a mating depression 32 in the upper surface of the filter support plate 26. Each male fitting 20 is then ultrasonically welded to the filter support plate 26 thereby forming a seal at the bottom of each well 14 surrounding the filter medium. With the filter support plate 26 in place, the inner skirt 24 extends below same a sufficient distance to provide the aforementioned clearance, suitably about 1 mm. Secondly, the inner skirt 24 provides a continuous hermetic seal around the periphery of the top surface of a collection plate. Thus, the inner skirt 24 has downwardly opening channel 28 in which is carried a bead of a suitable gasket material, e.g. a silicone elastomer 56.
In an alternative embodiment, as shown in FIG. 7 and now considered an improvement over that just described, a gasket 57 provides the seal between the manifold plate 10 and a microtiter plate 54 (or another manifold plate 10). The gasket 57 has a lip 59 which fits under the end of the inner skirt 24.
For the purpose of evacuating the space underneath the filter support plate the apparatus of the present invention is provided with a vacuum port 50 which extends through skirts 22 and 24 as shown in FIG. 2. The area beneath the filter support plate 26 is also evacuated through port 50 by provision of a number of openings between the edge of the filter plate 26 and the inner skirt 24 of the manifold plate 10. In other words, as shown in FIGS. 3 and 5, the filter support plate is provided with several notches 52 at its periphery. A luer taper petcock (not shown) or any other suitable vacuum fitting may be press fit or threaded into the vacuum port 50 to provide the necessary connection. Thus, the apparatus of the present invention provides its own vacuum manifold and dispenses with the need for investment in the rather expensive conventional vacuum manifolds heretofore used in connection with the prior art microfiltration apparatus.
As shown in FIG. 6, the manifold plate 10 with the filter support plate 26 attached within inner skirt 24, is designed to align with and mate with a conventional microtiter plate indicated at 54 in FIG. 6. Thus, each of the 96 wells of the manifold plate will be coaxial with one of the 96 wells of a conventional titer plate. As noted above, a hermetic seal between the top planar surface of the microtiter plate 54 and the lower end of skirt 24 is provided by a bead of gasket material, e.g. a silicone elastomer 56, molded to attach in a downwardly opening channel 28, as shown in FIG. 6, or a gasket 57 as shown in FIG. 7. As is shown in FIG. 12, the whole assembly may be optionally held together with a number of C-clips 58, one of which is shown in more detail in FIG. 13. Protrusions 60 and 62 of C-clip 58 are received, respectively, in a cutout or indented groove 64 provided at the periphery of the manifold plate 10 and the bottom skirt of a microtiter plate, or a cutout 65 in the bottom of another manifold plate.
FIG. 10 depicts an alternative embodiment which, at the present point in time, is the most preferred embodiment. As shown in FIG. 10 the manifold plate 11 has annular male members 21 which are substantially the same length as members 20 in the previously described embodiments but the webs 23 connecting same extend downward from the planar surface 12 only as far as the terminus of counterbore 18. Otherwise, manifold plate 11 in the embodiment of FIG. 10 is similar to manifold plate 10 of the previously described embodiments. Likewise, the filter support plate 27 is similar to the filter support plate 26, except that instead of depressions 32, the filter support plate 27 carries an array of annular members 29, each of which mates with a male member 21 to provide a press fit heremetic seal therebetween. Another difference in the filter support plate 27 is that indented areas ("diamonds") 55 have been omitted so that the entire area surrounding the annuli 29 is of uniform thickness. Because no web extends between the press fit areas, the annular members 29 may swell due to the pressure of the press fit without causing warpage of the manifold plate.
Another embodiment of the present invention is illustrated in FIG. 11 wherein elements identical to those of the embodiments of FIGS. 1-9 are indicated by the same reference numerals. Instead of a filter support plate, planar bottom members 92 are provided for each well 14 and are formed integrally therewith as a single molded piece. The bottom members 92 each present a filter support surface 94 having a filtrate collection channel 38 as in the previously-described embodiment. A disc of filter medium 70 is placed in the bottom of each well 14 against filter support surface 94 and is sealed in place around its periphery by press-fitting an annular member 96 within the well 14. It should be noted that the annular member 96 provides an inner well geometry identical to that of the first-described embodiment, inclusive of the "S"-shaped shoulder 17.
In embodiments where the filter support plate 26 and the manifold plate 10 are separately formed and then welded together, a single sheet of membrane filter, of dimensions approximating those of the filter support plate, may be laid on top of the filter support plate 26 and then the whole is press-fit against the bottom of manifold plate 10. In such an embodiment, as depicted in FIG. 8, as the male fitting member 20 is forced into the depression 32, it cuts a circular piece of filter 70 out of the sheet and forces it to the bottom of the depression 32. In other words, male member 20 serves as a punch and the depression 32 serves as a die for cutting the filter. In contrast, in the single piece construction shown in FIG. 11, discs of filter medium 70 must be placed into each well 14 by punching or other means. Of course, in the two piece constructions of FIGS. 1-10 it is also possible to use separately formed disks of filter medium 70.
The nature of the filter medium 70 will vary widely depending upon the end use for which the microfiltration apparatus in intended. For example, for microchromatography applications the filter medium 70 may be a 20 micron fibrous paper of paper pulp, glass, cellulose acetate, or a mixture thereof. For cell culturing a hydrophilic microporous membrane having a pore size of 0.5-1 micron, preferably 0.6 microns, is preferred. For biological binding assays any affinity reactive membrane, e.g. nitrocellulose, may be used.
FIG. 9 shows the manifold plate 14 and filter support plate 26 inverted for receiving a punch 72. The punch 72 is of a diameter approximately equal to that of circumscribed area 48 and bore 16. It can be seen that punch 72 will mate with pins 44, 45, and 46 (and 47, not shown) which serve as a guide for receiving and guiding punch 72. As punch 72 passes through filter plate 26 it will push, ahead of it, a cut out portion 49 which will serve as the cutting punch, shearing the filter, and as a piston to wipe the walls of bore 16 thereby cleaning off any residue thereon. The bore 16 serves as a die working together with the punch to shear the support plate and filter. The punched portion of the filter medium 70, with whatever has been deposited thereon or bound thereto during the course of the assay, is pushed down out of bore 16, leaving behind an annular piece of filter medium pressed beneath male member 20 in the first embodiment and beneath annular member 96 in the second embodiment. If the well 14 is formed of a single, constant diameter, i.e. without a shoulder 17, bore, the cut-out portion of the filter plate 29 will wipe a substantial length of the well.
FIG. 14 shows one punch 72 of a linear array of eight punches mounted within a punch holder 74 which allows the punches 72 to move slightly within a horizontal plane to properly align themselves with the axis of a well 14. The punches 72 are aligned with a horizontal row of eight wells 14 and operated in sequence to punch out areas 49 one at a time and then stepped to the next horizontal row of wells where the punching operation is repeated.
An example of an immunoassay that can be performed using the apparatus of the present invention is a sandwich EIA. The apparatus for performing the immunoassay would include: (1) a manifold plate having an upper planar surface and an array of filtering wells for receiving liquid samples to be filtered, each of the wells being closed at its bottom by a planar member providing a filter support surface for a filter medium; inner and outer skirts depending from the upper planar surface and surrounding the array of filtering wells, the outer skirt being adapted to mate with the exterior sidewalls of a collection plate, and the inner skirt terminating at a lower rim and being sufficiently long to maintain a fixed space between the well bottoms and a planar surface of a collection plate engaged by the lower rim; sealing means for forming a hermetic seal between the lower rim of the inner skirt and the top of the collection plate; the inner skirt defining an interior space within the manifold plate; a drain port, associated with the bottom of each of the filtering well bottoms, for draining filtrate from the associated well; and a vacuum port for evacuating the interior and fixed spaces thereby drawing filtrate through the drain ports; (2) a filter medium disposed in the bottom of each of the filtering wells of the manifold plate; (3) a waste receiving tray sized to engage and seal hermetically to the inner skirt of the manifold plate; and (4) a conventional multiwell microtiter plate suited to optical measurement which will seal hermetically to the inner skirt of the manifold plate.
A primary antibody is adsorbed or covalently immobilized to the filter medium. Alternatively, equal aliquots of a suspension containing microbeads with primary antibody adsorbed or covalently immobilized are added to each of the filtering wells. In order to perform the immunoassay, the manifold plate is placed on top of the waste receiving tray. A sample containing antigen to be assayed is then placed within the filtering wells and the sample is filtered through the filter medium at a controlled rate by applying a vacuum beneath the filter support plate. The antigen of interest is thus captured and the remaining sample is passed into the waste receiving tray. A solution containing an excess of a second antibody conjugated to an enzyme is then added to each filtering well and again filtered through the filter medium at a controlled rate. Several volumes of a wash buffer solution are then filtered through each filtering well to remove any unbound enzyme conjugate. The waste receiving tray is then removed from under the manifold plate and replaced with the conventional multiwell microtiter plate. An excess of colorless enzyme substrate solution is added to each filtering well and again filtered through at a controlled rate by vacuum. Optionally, a volume of wash buffer solution may be filtered through the filtering wells to quantitatively transfer all enzyme product to the microtiter plate. The microtiter plate is then read on a conventional multiwell spectrophotometric plate reader. Thus, a quantitative assay for anitgen is obtained.
CELL CULTURING
FIG. 15 depicts two manifold plate assemblies 10 and 10' in accordance with the present invention combined with a conventional microtiter plate 54 in an arrangement suitable for cell cultivation. Both the upper and the lower manifold plate assemblies 10 and 10' are provided with a filter medium 70 which may be any suitable hydrophilic microporous membrane, e.g. a cellulose ester or nylon membrane. The membrane will typically have a pore size of 0.2-1 micron, preferably 0.6 microns. Cells and cell culture medium 76 are placed into each of the 96 wells of the lower manifold plate assembly 10' for incubation. Nutrient, drugs to be tested or labeled precursor in liquid form 78, may be placed in the wells of the upper manifold plate/filter support plate assembly 10 from time to time for feeding to the cell cultures in the wells of the lower manifold plate 10'. The nutrient liquid may be sterilized as it passes through the microporous membrane 70 in the upper manifold plate 10, if that membrane has a pore size of 0.2 μ or less. The diameter of the filtrate passage 42 in each pin 44 is such that the pressure of the hydrostatic head of the culture medium in each well of the lower manifold plate is offset by the capillary force within passage 42 and the force of drop adhesion thereto. The result is that there will be transfer of only small volumes of liquid from the cell culture medium in plate 10' into the wells of the microtiter plate 54, until such time as a suitable vacuum is applied to the lower manifold plate 10'. A liquid head corresponding to a volume of 50 μl-100 μl will remain in wells 16 of the lower manifold plate 10 when plates 10 and 10' are vented to atmosphere. If a vacuum is applied only to plate 10, then fluid added to plate 10 will immediately filter into the wells of plate 10' and none of the volume in the wells of plate 10' will filter into plate 54. If a higher vacuum is applied to plate 10' or if plate 10 is vented and vacuum is applied to 10' then all the volume in the wells of plate 10' will transfer to the wells of plate 54.
Thus, the arrangement shown in FIG. 15 dispenses with the absolute need for using a sterile hood during feeding of nutrients to a microculture plate. Further, there is no loss of cells in feeding or harvesting as occurs by supernate aspiration in the prior art methods.
RADIOGRAPHY
FIGS. 16 and 17 depict two different methods for adapting the present invention for use in radiography. A radiolabeled species is collected on a suitable filter medium in a manifold plate assembly in accordance with the present invention. After removal of the filtrate by vacuum, the manifold plate assembly may be placed in a molded, light impervious, e.g. black, cassette 80 with a suitable film (Kodak "X-OMAT") contained therein as depicted in FIG. 16. The film is thereby exposed to whatever radiolabeled species might be present on or in the filter medium 70. In an alternative embodiment illustrated in FIG. 17, after recovery of the radiolabeled species on the filter medium 70, the manifold plate has its top planar surface covered with a plastic film such a "SARAN" 84 and the whole is then inverted and punched with cut elements 49 being held suspended on the plastic film 84. After punching, the whole may be placed inverted into a light impervious cassette 80 containing a suitable film 82, e.g. Kodak "X-OMAT", backed by an enhancing screen 86 for exposure of the film.
MICROCHROMATOGRAPHY
The apparatus of the present invention may be adapted for use in microchromatography techniques by filling wells 14 of a manifold plate 10 with ion exchange, reverse phase or desalting or other media. A sheet of thin "POREX" or other suitable porous media 88 is then placed on a steel die plate with 96 holes equal in diameter either to bore 16 or counterbore 18, aligned with the filtering wells 14, which die plate, in turn, rests on the top planar surface of manifold plate 10 and the "POREX" sheet is punched through using a punch similar to that shown in FIG. 12. The result is a compacted column of chromatography media 90 in each well 14, held in its compacted condition by the "POREX" disk 88, as shown in FIG. 18. A number of such microchromatography manifold plates may be assembled together, one above the other, and sealed to each other by gasket 56 or 57 as previously described to allow for multistep isolation of a particular species. Alternatively a binding and washing cycle may be performed in one plate, with elution into a second plate containing a different medium, and the cycle repeated as needed.
The embodiments shown in FIGS. 15-18 may also include pins 45, 46 and 47 (not shown).
The invention may be embodied in other specific forms without departing from the spirit or essential characteristics thereof. The present embodiments are therefore to be considered in all respects as illustrative and not restrictive, the scope of the invention being indicated by the appended claims rather than by the foregoing description, and all changes which come within the meaning and range of equivalency of the claims are therefore intended to be embraced therein. | The present invention relates to a multiwell apparatus for biological and biochemical analysis which provides for separate collection of filtrate from each well, without cross-contamination therebetween. The present invention provides a manifold plate having an array of filtering wells, each of the wells being closed at its bottom by a planar bottom member providing a filter support surface. A discharge nozzle of passageway depends from each well bottom (planar bottom member) in a direction normal thereto, with one such discharge nozzle or port being provided in fluid communication with each filtering well. Each of these filtrate nozzles or drain ports extends from the lower surface of the planar bottom member to such an extent that it will enter into the well of a conventional multiwell, e.g., microtiter, plate in alignment therewith and mate with the sidewall of the aligned well of the multiwell plate. In this manner, the filtrate can be delivered to the collection well of the multiwell plate as a steady stream, in the manner one would use a pipette, rather than dropwise. The ability to quantitatively collect filtrate into a receiving multiwell plate provides options for improved immunoassays, nucleic acid probe assays and other test procedures. | 2 |
FIELD OF THE INVENTION
[0001] The present invention relates to systems and apparatus for dust and other particulate removal from the boundary layer of moving webs, including nonwoven and paper webs.
BACKGROUND OF THE INVENTION
[0002] Paper machines, particularly machines making tissue paper such as toilet tissue, facial tissue, and paper towels, create substantial amounts of dust. Dust and other particulates gets carried in the boundary layer of a moving web but gets dislodged when the web is disturbed or changes directions. Dislodged dust that accumulates on the machinery can interfere with correct operation, lead to product quality problems in some circumstances, and can hinder or require maintenance. Additionally dust that is transferred into the air can also represent a fire hazard, and its inhalation can cause health problems for workers.
[0003] Much effort has been directed to the development of dust hoods for vacuuming dust laden air from parts of such machines. However, such devices are themselves imperfect in operation and can require substantial power consumption as well as being the source of noise.
[0004] One problem with methods involving vacuum applied to the web surface is that the vacuum, in addition to removing airborne fibers can partially dislodge fibers in the web, creating loose or loosened fibers which then can become airborne downstream from the vacuum area.
[0005] There is thus a continuing need for a method and apparatus for removing dust in a power-efficient, environmentally friendly manner.
SUMMARY OF THE INVENTION
[0006] A method for removing dust-carrying air from a moving paper web is disclosed. The method includes the steps of:
[0007] providing a moving web, the web having a first side and a second side, the web moving at a sufficient rate to produce a boundary layer of adjacent dust-carrying air;
[0008] providing a NACA duct, the NACA duct having an intake opening and walls that diverge in increasing cross-sectional area to an exhaust opening having greater cross sectional area than the intake opening;
[0009] submerging the intake opening into the boundary layer to scavenge dust-carrying air from the boundary layer.
BRIEF DESCRIPTION OF THE DRAWINGS
[0010] FIGS. 1 a and 1 b are schematic representations of a typical NACA duct.
[0011] FIG. 2 is a side view of one embodiment of an apparatus of the present invention.
[0012] FIG. 3 is a top view of one embodiment of an apparatus of the present invention.
[0013] FIG. 4 is a top view of one embodiment of an apparatus of the present invention.
[0014] FIG. 5 is a side view of one embodiment of an apparatus of the present invention.
[0015] FIG. 6 is a side view of one embodiment of an apparatus of the present invention.
[0016] FIG. 7 is a perspective view of an embodiment of a NACA duct of the present invention.
[0017] FIG. 8 is a side view of one embodiment of an apparatus of the present invention.
[0018] FIG. 9 is a side view of one embodiment of an apparatus of the present invention.
[0019] FIG. 10 is a side view of one embodiment of an apparatus of the present invention.
[0020] FIG. 11 is a diagrammatic representation of a nested NACA duct arrangement.
DETAILED DESCRIPTION OF THE INVENTION
[0021] In a typical paper machine for making absorbent tissue, such as bath tissue, facial tissue, or paper towels there is a drying section typically in which the paper web is adhered to the surface of a rotating Yankee dryer and lead to a creping doctor blade. There, the web is creped off the Yankee dryer by the creping blade. The creped paper web can then be wound onto a reel, which is often referred to as a parent roll. At creping, and in other parts of the dry paper-making path, dust separates from the paper web. Part of this dust will be entrained in a boundary layer on each side of the creped web that can run forward at a velocity close to 25 m/s. This dust can become dislodged from the boundary layer and accumulate on the machinery. This accumulation can interfere with correct operation, lead to product quality problems, hinder maintenance, and may also present a fire hazard. Dust that is transferred into the air can also represent a fire hazard, and additionally can be breathed by workers.
[0022] Similar problems with respect to dust and particulate creation and its removal are observed also in the converting of such paper webs, as well as in the manufacture and converting of other webs like nonwovens and other webs made of filaments.
[0023] Accordingly, whereas the present invention can find beneficial application for removal of particulate-carrying air, including dust-laden air, on various web production and conversion applications, the invention will be described below primarily in its operates for catching and extracting at least a portion of the dust-laden air in a boundary layer of a moving paper web. Removal of particulate-carrying air, including dust-laden air, can be described as scavenging.
[0024] The invention utilizes a NACA duct. NACA ducts are well known for the purpose of drawing off boundary layer air in moving vehicles without disrupting airflow otherwise. The design and construction of NACA ducts are well-known, for example, a description of NACA ducts can be found in the October 1945 National Advisory Committee for Aeronautics Advance Confidentiality Report #5i20 (NACA ACR No. 5i20) “An Experimental Investigation of NACA Submerged-Duct Entrances” by Charles W Frick, Wallace F. Davis, Lauros M. Randall, and Ernest A Mossman. This document is available on the interne as a downloadable web archive PDF file at http://naca.central.cranfield.ac.uk/report.php?NID=2176.
[0025] Characteristic for a NACA-duct is an intake opening having a curved and divergent contour. The part of the intake opening which is submerged in the boundary layer can be configured as a ramp-like surface having an angle relative to an outer surface reference, such as, in the instant application, a moving web. There can be a sharp edge transition in between the outer surface reference and the inner ramp-like surface. A NACA duct contains as well an inlet profile adjacent the air intake. NACA duct functionality is based on the principle of generating rotating air vortices on the opening edges of the air intake, which help guide the boundary layer into the duct.
[0026] In the present invention the term “NACA duct” includes NACA ducts having curvilinear-shaped intake opening sidewalls, including curvilinear-shaped according to the dimensions disclosed in the above-mentioned October 1945 National Advisory Committee for Aeronautics Advance Confidentiality Report. As used herein, the term NACA duct also includes ducts having substantially straight intake opening sidewalls. Ducts having substantially straight intake opening sidewalls can approximate NACA ducts having curvilinear-shaped intake opening sidewalls. In plan view, in a substantially straight walled version, the substantially straight sidewalls of a NACA duct form a trapezoidal shape, with opposite lengthwise sidewalls diverging from a relatively short upstream wall to a relatively long downstream wall.
[0027] FIG. 1 a shows a sectional view of a typical NACA air intake. An intake opening 4 extends down to a ramp-like inlet surface 6 . An airduct 1 joins the ramped inlet surface 6 with a profiled edge 8 and directs the air from the environment into this airduct. The airflow 3 passes the intake opening 4 and enters the airduct 1 , with only minimal disturbance of the airflow.
[0028] FIG. 1 b . shows a top view of the opening 4 . The divergent opening contour 5 is apparent, where the ramped inlet surface 6 has typically the same contour. Vertical sidewalls 7 of the opening 1 defined by the contour of the opening 5 and the ramped inlet surface 6 are primarily perpendicular to the base surface 2 . The airflow 3 passes the opening 4 and enters by the formation of counter rotating vortices 9 in the airduct 1 .
[0029] In an embodiment of the invention shown in FIG. 2 , a system and apparatus 10 of the present invention includes a NACA duct 12 in operational proximity to a moving web 14 . NACA duct 12 is shown in cross-section to better indicate its operation. Moving web 14 has a boundary layer 16 on each side thereof, the boundary layer having a thickness related to the speed of the moving web by well known equations relating to the Reynolds number of air. For current processes on commercial paper machines, the boundary layer for a paper web running at about 700 m/min can be from about 1 mm to about 25 mm thick, i.e., the boundary layer can extend from 1 mm to about 25 mm perpendicularly from the surface of the web 14 . The boundary layer can be about 5 mm, 7 mm, 9 mm, 11 mm, 13 mm, 15 mm, 17 mm, 19 mm 21 mm or 23 mm thick.
[0030] NACA ducts have an intake opening 18 (corresponding to intake opening 4 of FIG. 1 a ) having walls that diverge in increasing cross-sectional area to an exhaust opening 20 having greater cross-sectional area than the intake opening. A smooth, rounded edge 22 allows a smooth transition of air passing the NACA duct, permitting some of the boundary layer to smoothly enter toward exhaust opening 20 , and some of the air to pass relatively undisturbed. As the boundary layer traverses the intake opening it is guided over the angularly oriented diverging walls to create rotating vortices directed away from the web. These rotating vortices carry dust-laden air to the exhaust opening. A NACA duct positioned for effective operation to effectively remove a portion of the air of a boundary layer of a moving web can be said to be disposed in operation relationship to the moving web.
[0031] In an embodiment dust removal can be aided by a partial pressure, such as by vacuum, at the exhaust opening 20 . Vacuum can be supplied via known vacuum means, and can be balanced such that the mass balance of air entering the intake opening and air exiting the exhaust opening remains substantially equal. A vacuum generating apparatus can be situated relatively closely to exhaust opening, or exhaust can be effected via ductwork and/or manifolds such that the vacuum generating apparatus can be situated remotely and supply vacuum via the ductwork and/or manifolds.
[0032] A NACA duct 12 is positioned in operational proximity to the moving web, which means the NACA duct is positioned in a non-contacting relationship to the paper web moving in a machine direction (MD), and that its inlet 18 is submerged in the dust-carrying boundary layer 16 with the narrowest portion of the intake opening being positioned upstream with respect to the MD. When positioned in operational proximity there is no direct contact with the moving web and no normal forces are applied to the web by the NACA duct, both conditions of which tend to produce more dust by virtue of disturbing fibers on the web. For example, normal forces applied by vacuum or shear forces from web-contacting components contacting a moving web can partially dislodge fibers that later become airborne, or fully dislodge fibers that are not removed upon separation from the web. Further, web-contacting portions of web handling equipment, including dust-removal equipment, disrupts the laminar flow of the boundary layer, causing additional dust-laden air to be directed out of the boundary layer. Dust from such re-directed dust-laden air can then settle on equipment or remain airborne as an environmental concern.
[0033] Although FIG. 2 shows a NACA duct on only one side of a moving web, a NACA duct can be placed on both sides of a moving web as shown in FIGS. 8 and 9 , described in more detail below. In addition, as shown in FIGS. 3 and 4 , a plurality of NACA ducts can be utilized. In the embodiment shown in FIG. 3 , a series of closely spaced NACA ducts 12 can be disposed across a portion of the width of web 14 , and can be disposed substantially across the entire width of web 14 .
[0034] Because the widest portion of the intake opening 18 of each NACA duct can be relatively narrow in a direction corresponding to the width, or cross direction (CD) of web 14 , in another embodiment, as shown in FIG. 4 , a plurality of NACA ducts 12 can be staggered in CD-oriented rows of substantially side-by-side NACA ducts 12 , thereby increasing the area of total web boundary layer impacted by the NACA ducts. While two CD-oriented rows are shown in FIG. 4 , in other embodiments, more than two CD-oriented rows can be employed as desired. In general, the size and spacing of NACA ducts 12 can be selected to ensure substantially 100% of the CD of the web 14 is covered by a NACA duct intake opening 18 .
[0035] As shown in FIG. 5 , in an embodiment, the NACA duct 12 can have on its upstream edge a converging plate 24 that can span in a width-wise dimension at least the width of intake opening 18 . Converging plate 24 can have sufficient length and can be angled sufficiently with respect to the plane of moving web 14 such that leading edge 22 can be outside of the boundary layer. In general angle θ can be from about 10° to about 50°. Converging plate 24 enhances the operation of the NACA duct by smoothly diverting more of the boundary layer into intake opening 18 .
[0036] In an embodiment, the dust removal system and apparatus of the present invention can be utilized at a position of the web path in which the web is turning over a roller. A moving web going over a roller can be more stable, e.g., less prone to flutter, than a web spanning a free span. The added web stability imparted by a moving web in tension traversing a roller can be beneficially utilized by the NACA duct of the present invention by allowing the NACA duct to be placed closer to the web surface without inadvertently contacting the web surface. Additionally, the centrifugal forces imparted on the particles on the outer surface of the web will increase the effectiveness of this arrangement. As shown in FIG. 6 , moving web 14 can move in a machine direction (MD) over a roller 26 such that the web path is changed. The change in web path can be from 10° to about 180°. A NACA duct 12 can have a shape such that the NACA ducts can conform substantially to the curvature of the web 12 around roller 26 .
[0037] An embodiment of a NACA duct, specifically a NACA duct 12 as depicted in FIG. 6 , is shown in FIG. 7 . FIG. 7 shows a NACA duct 12 from a perspective of looking at the web-facing surface. Three NACA ducts 12 are shown in a substantially side-by-side relationship. FIG. 7 shows the convergence plate 24 , the diverging sidewalls of each intake opening 18 , as well as the exhaust openings 20 . Although FIG. 7 shows a curved version of the NACA ducts 12 of the present invention, the same structure(s) is/are present in a flattened version, as depicted in FIG. 2 .
[0038] In an embodiment of the invention, FIG. 8 shows an arrangement of two NACA ducts 12 , one on each side of a moving web 14 , the web 14 moving into a nip roll arrangement 30 . Nip roll arrangement 30 has two rolls, 32 and 34 between which web 14 traverses. Nip rolls 32 and 34 can be calendar rolls, emboss rolls, or any other of typical nip rolls used in web forming processes. The advantage of placing NACA ducts before a web enters the nip of nip rollers is that the dust-laden air in the boundary layer can be scavenged before the boundary layer is disrupted by the nip roll arrangement 30 .
[0039] In another embodiment of the invention, FIG. 9 shows an arrangement of two NACA ducts 12 , one on each side of a moving web 14 , the web 14 moving away from a nip roll arrangement 30 . Nip roll arrangement 30 has two rolls, 32 and 34 between which web 14 traverses. Nip rolls 32 and 34 can be calendar rolls, emboss rolls, or any other of typical nip rolls used in web forming or converting processes. These types of process typically liberate new dust from the web material which is then carried within the newly formed boundary layer after the nip. The advantage of placing NACA ducts after a web exits the nip of nip rollers is that this new dust that enters the boundary layer can be scavenged shortly after a new boundary layer forms after the nip roll arrangement 30 .
[0040] In another embodiment of the invention, FIG. 10 shows an arrangement of a NACA duct 12 in operative relationship to a first side of a moving web 14 . On the other, second, side of the moving web 14 is disposed a dimpled plate 36 , the dimpled plate being of sufficient size, design, and placement with respect to the web, as is known in the art, to ensure better controlled web handling. A dimpled plate on the opposite of web 14 from NACA duct 12 can stabilize the web, helping to prevent flutter and other web movement in an unsupported span, for example.
[0041] In an embodiment, the size of a plurality of NACA ducts arranged generally in the CD web direction can be modified to get substantially full CD web coverage while utilizing a minimum length of total web coverage in the MD direction, LMD. By optimizing the sizes of the plurality of NACA ducts to minimize LMD, full web particulate collection can be utilized at any web span of greater length than LMD. As shown in the diagram of FIG. 11 , it is believed that by disposing a plurality of primary NACA ducts 12 a in an adjacent side-by-side relationship, and by placing a half-size secondary NACA duct 12 b between each primary NACA duct 21 a such that the leading edge of all the intake openings 18 lie substantially on the same CD-oriented line, coverage for particulate collection can be maximized. Such a staggered, nested relationship of NACA ducts can minimize the space requirements for full-web-width dust collection.
[0042] As shown in FIG. 11 , length Xa of the intake openings 18 of NACA ducts 12 a can be twice the length Xb of the intake openings 18 of NACA duct 12 b and the width Ya of the intake openings 18 of NACA ducts 12 a can be twice the width Yb of the intake openings 18 of NACA duct 12 b . In the configuration shown and described, maximum nesting of NACA ducts can be achieved. In general, the length Xb of the intake openings 18 of NACA ducts 12 b can be about 30% to 80% the length Xa of the intake openings 18 of NACA duct 12 a and the width Yb of the intake openings 18 of NACA ducts 12 b can be about 30% to 80% the width Ya of the intake openings 18 of NACA duct 12 a.
[0043] The dimensions and values disclosed herein are not to be understood as being strictly limited to the exact numerical values recited. Instead, unless otherwise specified, each such dimension is intended to mean both the recited value and a functionally equivalent range surrounding that value. For example, a dimension disclosed as “40 mm” is intended to mean “about 40 mm.”
[0044] Every document cited herein, including any cross referenced or related patent or application, is hereby incorporated herein by reference in its entirety unless expressly excluded or otherwise limited. The citation of any document is not an admission that it is prior art with respect to any invention disclosed or claimed herein or that it alone, or in any combination with any other reference or references, teaches, suggests or discloses any such invention. Further, to the extent that any meaning or definition of a term in this document conflicts with any meaning or definition of the same term in a document incorporated by reference, the meaning or definition assigned to that term in this document shall govern.
[0045] While particular embodiments of the present invention have been illustrated and described, it would be obvious to those skilled in the art that various other changes and modifications can be made without departing from the spirit and scope of the invention. It is therefore intended to cover in the appended claims all such changes and modifications that are within the scope of this invention. | A method for removing dust-carrying air from a moving paper web is disclosed. The method includes the steps of: providing a moving web, the web having a first side and a second side, the web moving at a sufficient rate to produce a boundary layer of adjacent dust-carrying air; providing a NACA duct, the NACA duct having an intake opening and walls that diverge in increasing cross-sectional area to an exhaust opening having greater cross sectional area than the intake opening; and submerging the intake opening into the boundary layer to scavenge dust-carrying air from the boundary layer. | 1 |
CROSS REFERENCE TO RELATED PATENT APPLICATIONS
This application claims priority to U.S. Provisional Patent Application No. 61/728,905, filed on Nov. 21, 2012, entitled “Process and Composition for Removing Substances from Substrates,” which is hereby incorporated by reference in its entirety.
STATEMENT OF JOINT DEVELOPMENT
This invention was created pursuant to a joint development agreement between Eastman Chemical Co. and EV Group. The aforementioned joint development agreement was in effect on or before the date the claimed invention was made, and the claimed invention was made as a result of activities undertaken within the scope of the joint development agreement.
BACKGROUND
Various polymers may be used in the manufacture of electronic devices, including, for instance, photoresists and organic-based dielectrics. Photoresists, for example, may be used throughout semiconductor device fabrication in photolithographic operations. A photoresist may be exposed to actinic radiation through a photomask. Where a positive-acting resist is used, exposure may cause a chemical reaction within the material resulting in a solubility increase in aqueous alkali, allowing it to be dissolved and rinsed away with developer. Where a negative-acting resist is used, cross-linking of the polymer may occur in the exposed regions while leaving unexposed regions unchanged. The unexposed regions may be subject to dissolution and rinsing by a suitable developer chemistry. Following development, a resist mask may be left behind. The design and geometry of the resist mask may depend upon the positive or negative tone of the resist; positive tone resist may match the design of the photomask, while a negative tone resist may provide a pattern that is opposite the photomask design.
Photoresists are used extensively in many applications, including the packaging of microelectronic devices and in manufacturing compound semiconductors.
In wafer level packaging, solder is applied directly to wafers that have completed the fabrication of the microelectronic devices but have not been diced into individual chips. Photoresist is used as the mask to define the placement of the solder on the wafers. After solder is deposited onto the wafer, the photoresist must be removed before the next step in the packaging process can occur. Typically in wafer level packaging, the photoresist is very thick, greater than 10 μm and sometimes as thick as 120 μm. The photoresist can be positive or negative, and can be applied either as a liquid or a dry film. In wafer level packaging, the use of thick dry film negative photoresist is common.
Due to the thickness and cross-linked nature of thick dry film negative photoresist, the removal of this material after solder deposition can be difficult. As a result of requirements for these process flows, immersion cleaning developed so that multiple wafers, typically 25 to 50 at a time, could be processed simultaneously and increase the tool throughput while still accommodating the long process time. The success with this type of processing allowed thick negative films to be successfully incorporated throughout the packaging process. However as wafer feature dimensions continue to be scaled down and the number of processes per wafer increases, the value of the wafer continues to increase. There comes a point when the best way to minimize risk of a bad result due to a process failure, is to process each wafer individually. Current immersion technology does not offer a removal solution with good cleaning characteristics, good compatibility and a process time that would meet practical throughput and cost-of-ownership targets of the industry.
In compound semiconductor processing, positive and negative spin on photoresist are commonly used. For example, for a lift off process, photoresist is applied and patterned, metal is deposited over the top of the pattern and the photoresist is removed, simultaneously removing metal on top of it. Moreover better stripping compositions that are compatible with the permanent wafer materials are needed for removal of the photoresist in a single wafer process.
Additionally, in compound semiconductor processing, patterns are formed in a layer on the substrate surface by patterning a photoresist on the surface and putting the substrate, with the patterned resist into a chamber with a plasma. The plasma can be selected to preferentially etch the open surface relative to the photoresist, thus creating the same pattern as the photoresist in the exposed layer. After the plasma treatment, photoresist as well as post etch residue, often organometallic and/or metal organic in nature, remains on the surface. Removal of the post etch residue at the same time as the remaining photoresist, while still maintaining compatibility with the permanent materials on the wafer surface would help ensure device performance.
SUMMARY
This summary is provided to introduce simplified concepts of compositions for removing substances from substrates such as, for example, photoresist from a semiconductor wafer. Additional details of example compositions are further described below in the Detailed Description. This summary is not intended to identify essential features of the claimed subject matter, nor is it intended for use in determining the scope of the claimed subject matter.
According to an embodiment, the present disclosure concerns a composition for removing substances from substrates. The composition may include from about 20 wt. % to about 90 wt. % of a polar aprotic solvent other than dimethyl sulfoxide; from about 1 wt. % to about 70 wt. % of at least one alkanolamine; less than about 3 wt. % a quaternary ammonium hydroxide; and a balance in water.
According to another embodiment, the present disclosure concerns a composition for removing a substances from substrates which may include from about 20 wt % to about 90 wt. % of a polar aprotic solvent; from about 10 wt % to about 70 wt. % of a first alkanolamine; from about 10 wt % to about 70 wt. % of a second alkanolamine; and a balance in water.
According to yet another embodiment, the present disclosure concerns a composition for removing substances from substrates which may include from about 20 wt. % to about 90 wt. % of a polar aprotic solvent; from about 1 wt. % to about 70 wt % of an amine or alkanolamine, and from about 1 ppm to about 10 wt % of a corrosion inhibitor.
DETAILED DESCRIPTION
The current invention describes compositions useful for removing organic substances (such as photoresists), from inorganic substrates, such as, for example, semiconductor wafers. The stripping compositions overcome disadvantages with current cleaning technologies and enable the successful removal of thick dry film negative photoresist from wafers.
The stripping solutions of the present disclosure may have application in the manufacture of a variety of devices including but not limited to semiconductor wafers, RF devices, hard drives, memory devices, MEMS, photovoltaics, Displays, LEDs, wafer level packaging, solder bump fabrication and memory resistor fabrication. Other applications in which the stripping solutions as disclosed may also be useful, include without limitation removal of photoresists (BEOL, FEOL), post-metallization, post etch residues, post implantation residues, lift-off (controlled corrosion), rework of passivation layers, and photoresist rework.
The terms “stripping”, “removing”, and “cleaning” are used interchangeably throughout this specification. Likewise, the terms “stripping composition”, “stripping solution”, and “cleaning composition” are used interchangeably. The indefinite articles “a” and “an” are intended to include both the singular and the plural. All ranges are inclusive and combinable in any order except where it is clear that such numerical ranges are constrained to add up to 100%, and each range includes all the integers within the range. The terms “weight percent” or “wt %” mean weight percent based on the total weight of the composition, unless otherwise indicated.
According to an embodiment, the present invention concerns a stripping solution comprising a polar aprotic solvent other than dimethyl sulfoxide, an amine or alkanolamine, and a quaternary ammonium hydroxide. Moreover, the balance of the stripping solution can be water. Additives may also be included such as metal corrosion inhibitors, or surfactants. Some stripping compositions additionally contain a secondary solvent.
The polar aprotic solvent is a polar aprotic solvent other than dimethyl sulfoxide and can be, but is not limited to, dimethylformamide; dimethylacetamide; 1-formylpiperidine; dimethylsulfone; n-methylpyrrolidone, n-cyclohexyl-2-pyrrolidone or mixtures thereof. According to an embodiment, the polar aprotic solvent is present in the stripping composition at an amount of from about 20 wt. % to about 90 wt. %; from about 35 wt. % to about 85 wt. % or from about 55 wt. % to about 80 wt. %. According to other embodiments, the polar aprotic solvent is present in an amount of at least 20 wt %, at least 30 wt. %, at least 40 wt. %, at least 50 wt. %, at least 60 wt. %, at least 70 wt. % or at least 80 wt. %. According to other embodiments, the polar aprotic solvent is present in an amount of no greater than 90 wt %, no greater than 80 wt. %, no greater than 70 wt. %, no greater than 60 wt. %, no greater than 50 wt. %, no greater than 40 wt. %, no greater than 30 wt. % or no greater than 20 wt. %.
According to an embodiment, the alkanolamines can have at least two carbon atoms, at least one amino substituent and at least one hydroxyl substituent, wherein the amino and hydroxyl substituents are attached to two different carbon atoms. According to an embodiment, the alkanolamine is present in the stripping composition at an amount of from about 1 wt. % to about 70 wt. %; from about 15 wt. % to about 60 wt. % or from about 25 wt. % to about 55 wt. %. According to other embodiments, the alkanolamine is present in an amount of less than 20 wt. %, or less than 10 wt. % or less than 5 wt. %. According to other embodiments, the alkanolamine is present in an amount of at least 1.0 wt %, at least 5 wt. %, at least 10 wt. %, at least 20 wt. %, at least 30 wt. %, at least 40 wt. %, at least 50 wt. % or at least 60 wt. %. According to other embodiments, the alkanolamine is present in an amount of no greater than 70 wt. %, no greater than 60 wt. %, no greater than 50 wt. %, no greater than 40 wt. %, no greater than 30 wt. %, no greater than 20 wt. %, no greater than 10 wt. % or no greater than 5 wt. %.
According to an embodiment, the compositions contain 1,2-alkanolamines having the formula:
where R 1 is hydrogen, (C 1 -C 4 ) alkyl, or (C 1 -C 4 ) alkylamino.
According to an embodiment, alkanolamines have at least two carbon atoms and have the amino and hydroxyl substituents on different carbon atoms. Suitable alkanolamines include, but are not limited to, aminoethylethanolamine, dimethylaminoethanol, monoethanolamine, N-methylethanolamine, N-ethylethanolamine, N-propylethanolamine, N-butylethanolamine, diethanolamine, triethanolamine, N-methyldiethanolamine, N-ethyldiethanolamine, isopropanolamine, diisopropanolamine, triisopropanolamine, N-methylisopropanolamine, N-ethylisopropanolamine, N-propylisopropanolamine, 2-aminopropane-1-ol, N-methyl-2-aminopropane-1-ol, N-ethyl-2-aminopropane-1-ol, 1-aminopropane-3-ol, N-methyl-1-aminopropane-3-ol, N-ethyl-1-aminopropane-3-ol, 1-aminobutane-2-ol, N-methyl-1-aminobutane-2-ol, N-ethyl-1-aminobutane-2-ol, 2-aminobutane-1-ol, N-methyl-2-aminobutane-1-ol, N-ethyl-2-aminobutane-1-ol, 3-aminobutane-1-ol, N-methyl-3-aminobutane-1-ol, N-ethyl-3-aminobutane-1-ol, 1-aminobutane-4-ol, N-methyl-1-aminobutane-4-ol, N-ethyl-1-aminobutane-4-ol, 1-amino-2-methylpropane-2-ol, 2-amino-2-methylpropane-1-ol, 1-aminopentane-4-ol, 2-amino-4-methylpentane-1-ol, 2-aminohexane-1-ol, 3-aminoheptane-4-ol, 1-aminooctane-2-ol, 5-aminooctane-4-ol, 1-aminopropane-2,3-diol, 2-aminopropane-1,3-diol, tris(oxymethyl)aminomethane, 1,2-diaminopropane-3-ol, 1,3-diaminopropane-2-ol, and 2-(2-aminoethoxy)ethanol and mixtures thereof.
According to another embodiment, amines include diethylenetriamine, triethylenetetramine, tetraethylenepentamine, dimethylbenzylamine, malonamide and mixtures thereof.
According to an embodiment, the quaternary ammonium hydroxide includes (C 1 -C 8 ) alkyl, benzyl and mixtures thereof. According to an embodiment, the quaternary ammonium hydroxide can be but is not limited to tetramethylammonium hydroxide; tetramethylammonium hydroxide pentahydrate; tetrabutylammonium hydroxide; benzyltrimethylammonium hydroxide; tetrapropylammonium; dimethyldipropyl-ammonium hydroxide; tetraethyl ammonium hydroxide; dimethyldiethyl ammonium hydroxide or mixtures thereof. According to embodiment, the quaternary ammonium hydroxide is present in the stripping composition at an amount of less than about 3.5 wt. %, less than about 2.5 wt. %, or less than about 2.0 wt. %.
Because some of the stripping solution's components can be provided as aqueous solutions, the composition can optionally contain small amounts of water. Hence, according to an embodiment, the balance of the stripping composition can be water. Moreover, water can be present in the stripping composition at an amount of less than about 15 wt. %, less than about 10 wt. %, or less than about 5 wt. %.
According to an embodiment, the compositions may contain about 20 wt. % to about 90 wt. % polar aprotic solvent, from about 10 wt. % to about 70 wt. % of the alkanolamine, less than about 3 wt % of the quaternary ammonium hydroxide and the balance in water.
According to an embodiment, the stripping compositions can also include a secondary solvent, a surfactant, and/or a corrosive inhibitor. Moreover, when used, a secondary solvent typically comprises from about 2 wt. % to about 35 wt. % of the composition. Secondary solvents may include but are not limited to ethylene glycol, diethylene glycol, propylene glycol, dipropyleneglycol, isopropylene glycol, diisopropylene glycol, butylene glycol, dibutylene glycol, ethylene glycol monomethyl ether, ethylene glycol monoethyl ether, ethylene glycol monopropylether, ethylene glycol monobutyl ether, ethylene glycol dimethyl ether, ethylene glycol diethyl ether, ethylene glycol dipropyl ether, ethylene glycol dibutyl ether, diethylene glycol monomethyl ether, diethylene glycol monoethyl ether, diethylene glycol monopropyl ether, diethylene glycol monoisopropyl ether, diethylene glycol monobutyl ether, diethylene glycol monoisobutyl ether, diethylene glycol monobenzyl ether, diethylene glycol diethyl ether, triethylene glycol monomethyl ether, triethylene glycol dimethyl ether, polyethylene glycol monomethyl ether, diethylene glycol methyl ethyl ether, triethylene glycol, ethylene glycol monomethyl ether acetate, ethylene glycol monoethyl acetate, propylene glycol monomethyl ether, propylene glycol dimethyl ether, propylene glycol monobutyl ether, dipropyelene glycol monomethyl ether, dipropylene glycol monopropyl ether, dipropylene glycol monoisopropyl ether, dipropylene glycol monobutyl ether, dipropylene glycol dimethyl ether, dipropylene glycol dipropyl ether, dipropylene glycol diisopropyl ether, tripropylene glycol and tripropylene glycol monomethyl ether, 1-methoxy-2-butanol, 2-methoxy-1-butanol, 2-methoxy-2-methyl-2-butanol, dioxane, trioxane, 1,1-dimethoxyethane, tetrahydrofuran, crown ethers and the like.
The stripping compositions can also contain an optional surfactant, for example, at levels in the range of about 0.01% to about 3%. One example of a fluorosurfactant is DuPont FSO (fluorinated telomere B monoether with polyethylene glycol (50%), ethylene glycol (25%), 1,4-dioxane (<0.1%), water 25%). Other useful surfactants include but are not limited to, Glycol Palmitate, Polysorbate 80, Polysorbate 60, Polysorbate 20, Sodium Lauryl Sulfate, Coco Glucoside, Lauryl-7 Sulfate, Sodium Lauryl Glucose Carboxylate, Lauryl Glucoside, Disodium Cocoyl Glutamate, Laureth-7 Citrate, Disodium Cocoamphodiacetate, nonionic Gemini surfactants including, for example, those sold under the tradename ENVIROGEM 360, nonionic fluorosurfactants including, for example, those sold under the tradename ZONYL FSO, ionic fluorinated surfactants including, for example, those sold under the tradename CAPSTONE FS-10, Oxirane polymer surfactants including, for example, those sold under the tradename SURFYNOL 2502, and poloxamine surfactants, including, for example, those sold under the tradename TETRONIC 701 and mixtures thereof.
The compositions can also optionally contain one or more corrosion inhibitors. A single corrosion inhibitor may be used or a combination of corrosion inhibitors may be used. Corrosion inhibitors may be included at levels ranging from about 1 ppm to about 10%.
Suitable corrosion inhibitors include, but are not limited to, dodecanedioic acid, undecanedioic acid, silicates such as ethyl silicate and tetramethyl ammonium silicate; aromatic hydroxyl compounds such as catechol and resorcinol; alkylcatechols such as methylcatechol, ethylcatechol and t-butylcatechol, phenols and pyrogallol; aromatic triazoles such as benzotriazole; alkylbenzotriazoles; carboxylic acids such as formic acid, acetic acid, propionic acid, butyric acid, isobutyric acid, oxalic acid, malonic acid, succinic acid, glutaric acid, maleic acid, fumaric acid, benzoic acid, phtahlic acid, 1,2,3-benzenetricarboxylic acid, glycolic acid, lactic acid, malic acid, citric acid, acetic anhydride, phthalic anhydride, maleic anhydride, succinic anhydride, salicylic acid, gallic acid, and gallic acid esters such as methyl gallate and propyl gallate; organic salts of carboxyl containing organic containing compounds described above, basic substances such as ethanolamine, trimethylamine, diethylamine and pyridines, such as 2-aminopyridine, and the like, and chelate compounds such as phosphoric acid-based chelate compounds including 1,2-propanediaminetetramethylene phosphonic acid and hydroxyethane phosphonic acid, carboxylic acid-based chelate compounds such as ethylenediaminetetraacetic acid and its sodium and ammonium salts, dihydroxyethylglycine and nitrilotriacetic acid, amine-based chelate compounds such as bipyridine, tetraphenylporphyrin and phenanthroline, and oxime-based chelate compounds such as dimethylglyoxime and diphenylglyoxime.
According to certain embodiments, the corrosive inhibitor includes a mixture of dodecanedioic acid, undecanedioic acid, and sebacic acid.
According to certain embodiments the stripping compositions display high loading capacities enabling the composition to remove higher levels of photoresists without the precipitation of solids. The loading capacity is defined as the number of cm 3 of photoresist or bilayer material that can be removed for each liter of stripping solution before material is re-deposited on the wafer or before residue remains on the wafer. For example, if 20 liters of a stripping solution can remove 300 cm 3 of photoresist before either redeposition occurs or residue remains on the wafer, the loading capacity is 300 cm 3 /20 liters=15 cm 3 /liter.
According to another embodiment, the stripping solution comprises a polar aprotic solvent; a first alkanolamine and a second alkanolamine. In another embodiment, the stripping solution includes a polar aprotic solvent; and at least two alkanolamines. Moreover, according to this embodiment, the polar aprotic solvent can be but is not limited to dimethyl sulfoxide; dimethylformamide; dimethylacetamide; 1-formylpiperidine; dimethylsulfone; n-methylpyrrolidone, n-cyclohexyl-2-pyrrolidone or mixtures thereof. According to this embodiment, the alkanolamines can be as described above. According to this embodiment, the compositions may contain about 20 wt, % to about 90 wt. % polar aprotic solvent, from about 1 wt. % to about 70 wt. % of a first alkanolamine, and from about 1 wt. % to about 70 wt. % of a second alkanolamine. According to an embodiment, the balance of the stripping solution can be in water. The stripping compositions can also contain secondary solvents, one or more corrosive inhibitors and one or more surfactants as described above.
According to this embodiment, the polar aprotic solvent is present in the stripping composition at an amount of from about 20 wt. % to about 90 wt. %; from about 35 wt. % to about 85 wt. % or from about 55 wt. % to about 80 wt. %. According to other embodiments, the polar aprotic solvent is present in an amount of at least 20 wt %, at least 30 wt. %, at least 40 wt. %, at least 50 wt. %, at least 60 wt. %, at least 70 wt. % or at least 80 wt. %. According to other embodiments, the polar aprotic solvent is present in an amount of no greater than 90 wt %, no greater than 80 wt. %, no greater than 70 wt. %, no greater than 60 wt. %, no greater than 50 wt. %, no greater than 40 wt. %, no greater than 30 wt. % or no greater than 20 wt. %.
According to this embodiment, each of the alkanolamines is present in the stripping composition at an amount of from about 1 wt. % to about 70 wt. %; from about 15 wt. % to about 60 wt. % or from about 25 wt. % to about 55 wt. %. Alternatively, each of the alkanolamines is present in an amount of less than 20 wt. %, or less than 10 wt. % or less than 5 wt. %. Alternatively still, each alkanolamine is present in an amount of at least 1 wt %, at least 5 wt. %, at least 10 wt. %, at least 20 wt. %, at least 30 wt. %, at least 40 wt. %, at least 50 wt. % or at least 60 wt. %.
According to yet another embodiment, the stripping solution comprises a polar aprotic solvent, an amine or alkanolamine, and a corrosion inhibitor. Moreover, according to this embodiment, the polar aprotic solvent can be but is not limited to dimethyl sulfoxide; dimethylformamide; dimethylacetamide; 1-formylpiperidine; dimethylsulfone; n-methylpyrrolidone, n-cyclohexyl-2-pyrrolidone or mixtures thereof. According to this embodiment, the polar aprotic solvent may be present in the stripping composition at an amount of from about 20 wt. % to about 90 wt. %; from about 35 wt. % to about 85 wt. % or from about 55 wt. % to about 80 wt. %. According to other embodiments, the polar aprotic solvent is present in an amount of at least 20 wt %, at least 30 wt. %, at least 40 wt. %, at least 50 wt. %, at least 60 wt. %, at least 70 wt. % or at least 80 wt. %. According to other embodiments, the polar aprotic solvent is present in an amount of no greater than 90 wt %, no greater than 80 wt. %, no greater than 70 wt. %, no greater than 60 wt. %, no greater than 50 wt. %, no greater than 40 wt. %, no greater than 30 wt. % or no greater than 20 wt. %.
According to embodiment, the alkanolamine or amine may be as listed above and may be present in the stripping composition at an amount of from about 1 wt. % to about 70 wt. %; from about 15 wt. % to about 60 wt. % or from about 25 wt. % to about 55 wt. %. According to other embodiments, the alkanolamine is present in an amount of less than 20 wt. %, or less than 10 wt. % or less than 5 wt. %. According to other embodiments, the alkanolamine is present in an amount of at least 1 wt %, at least 5 wt. %, at least 10 wt. %, at least 20 wt. %, at least 30 wt. %, at least 40 wt. %, at least 50 wt. % or at least 60 wt. %. According to other embodiments, the alkanolamine is present in an amount of no greater than 70 wt %, no greater than 60 wt. %, no greater than 50 wt. %, no greater than 40 wt. %, no greater than 30 wt. %, no greater than 20 wt. %, no greater than 10 wt. % or no greater than 5 wt. %.
According to certain embodiments, a single corrosion inhibitor may be used or a combination of corrosion inhibitors may be used. Corrosion inhibitors may be as listed above and may be included at levels ranging from about 1 ppm to about 10 wt. %, from about 100 ppm to about 7 wt %; or from about 500 ppm to about 5 wt. %.
According to certain embodiments, the polar aprotic solvent is 1-formylpiperidine, the alkanolamine is aminoethylethanolamine, and the corrosion inhibitor is a mixture of dodecanedioic acid, undecanedioic acid, and sebacic acid.
According to certain embodiments, the stripping solution comprises a polar aprotic solvent, such as for example, 1-formylpiperidine, an amine or alkanolamine, such as, for example, aminoethylethanolamine, and a corrosion inhibitor, such as, for example, a mixture of dodecanedioic acid, undecanedioic acid, and sebacic acid.
The stripping solutions according to the present invention can be used to remove photoresist from a number of different substrates and via a number of different methods including methods that involve immersing the substrate or via single wafer cleaning processes that coat a surface of the substrates (e.g. coat the surface of the substrate upon which the photoresist is located) one at a time. When immersing a substrate, agitation of the composition additionally facilitates photoresist removal. Agitation can be effected by mechanical stirring, circulating, or by bubbling an inert gas through the composition. Upon removal of the desired amount of photoresist, the substrate is removed from contact with the stripping solution and rinsed with water or an alcohol. For substrates having components subject to oxidation, rinsing is preferably done under an inert atmosphere. According to certain embodiments the stripping solutions accordingly have improved loading capacities for photoresist materials compared to current commercial products and are able to process a larger number of substrates with a given volume of stripping solution.
The stripping solutions provided in this disclosure can be used to remove polymeric resist materials present in a single layer or certain types of bilayer resists. For example, bilayer resists typically have either a first inorganic layer covered by a second polymeric layer or can have two polymeric layers. Utilizing the methods taught below, a single layer of polymeric resist can be effectively removed from a standard wafer having a single polymer layer. The same methods can also be used to remove a single polymer layer from a wafer having a bilayer composed of a first inorganic layer and a second or outer polymer layer. Finally, two polymer layers can be effectively removed from a wafer having a bilayer composed of two polymeric layers. The new dry stripping solutions can be used to remove one, two or more resist layers.
According to certain embodiments, the formulations according to the present invention can be employed in cleaning methods as described as follows. An exemplary method includes, but is not limited to the following. First a wafer with a thick dry film negative photoresist is coated with a volume of a formulated solvent-based mixture, where the thickness of the coating is sufficiently thick to enable removal of the thick dry film negative photoresist. The photoresist film is patterned with holes, inside which solder has been plated. The solder may be an alloy of Pb and Sn, Sn and Ag, or Cu pillars with a solder cap. The volume of formulation is such that the thickness of the liquid coating on top of the wafer is less than 4 mm thick, or may be less than 3.5 mm thick, or less than 3 mm thick, or less than 2.5 mm thick, or less than 2 mm thick. Alternatively, the thickness of the formulation is greater than 0.5 mm, greater than 1 mm, or greater than 1.5 mm. The thickness of the liquid coating may be thinner or thicker depending on the application and the resist or residue to be removed. In an embodiment, the thickness of the formulation that is sufficient for removing the photoresist can be defined by the ratio of the thickness of the formulation to the thickness of the photoresist film that is being removed. For thick photoresist, this ratio may be greater than 6:1, or greater than 8:1, or greater than 9:1 or greater than 10:1, or greater than 15:1, or greater than 19:1, or greater than 25:1. In certain embodiments, depending on the application and the resist or residue to be removed, the ratio may be even greater.
According to certain embodiments, the wafer may be held by a chuck that can rotate. The chuck may be such that the backside of the wafer is in contact almost completely with the same material, for example air, or an insulating polymer such as PEEK or PTFE. After the wafer is coated with the formulation, the formulation may be heated. Heating may occur by multiple methods, including convective heating by placement of a heat source within close proximity of the liquid surface, by irradiation with infrared radiation, by conductive heating either by contact to the backside of the wafer or contact directly to the liquid surface by a heat source. The formulation is heated to a temperature that allows for complete removal of the photoresist film within a sufficiently short amount of time. For example, the liquid may be heated to a temperature above 100° C., or above 105° C., or above 110° C., or above 115° C., or above 120° C. A sufficiently short amount of time may be less than 10 min for applying heat to the liquid, or less than 8 min, or less than 6 min, or less than 5 min, or less than 4 min, or less than 3 min, or less than 2 min. Again, the heating temperature and time may be longer or shorter depending on the application and the resist or residue to be removed, After heating for a sufficient amount of time, the heat source is removed. Next, the wafer may be rinsed to remove the formulation, dissolved photoresist in the formulation, and undissolved photoresist particles from the surface of the wafer. Rinsing may comprise multiple steps including dispensing a solvent or solvent-based mixture on the wafer while the wafer is spinning or stationary, dispensing water or an aqueous solution on the wafer while the wafer is spinning or stationary. The order in which these rinsing steps is applied may vary, and rinsing steps may be repeated multiple times. After the wafer is sufficiently rinsed, the wafer may be dried by spin drying. For example, isopropanol may be applied to the wafer prior, during, or after spin drying to facilitate complete drying. This process is used to remove photoresist from a single wafer. The process is repeated for additional wafers, using fresh, unused formulation for every wafer.
EXAMPLES
The stripping compositions according to the embodiments described above are further illustrated by, but not limited to, the following examples wherein all percentages given are by weight unless specified otherwise.
Example 1
This example concerns the removal of a 120 μm thick Asahi CX A240 dry film negative photoresist from a 300 mm wafer with Sn/Ag solder pillars. The composition of the stripping composition was 55 wt % monoethanolamine (MEA), 24.5 wt % n-methylpyrrolidone (NMP), 10 wt % dimethylaminoethanol (DMAE), 10 wt % 1-amino-2-propanol (MIPA), and 0.5 wt % resorcinol. The wafer was processed on an EVG-301 RS single wafer photoresist stripping tool. The wafer was placed in a chuck where ˜96% of the surface area of the backside of the wafer was in contact with air, and the outer diameter of the chuck forms a liquid containment barrier around the perimeter of the wafer. The outer 3 mm radius of the backside of the wafer was in contact with the chuck. The wafer was covered with 220 mL of the stripping composition. The inner radius of the chuck is ˜4 mm larger than the outer radius of the wafer. The stripping composition fills the total inner diameter of the chuck, i.e., the stripping composition coats the entire top surface of the wafer and extends beyond the total diameter of the wafer to fill the total inner diameter of the chuck. Therefore, the thickness of the stripping composition on top of the wafer was ˜2.95 mm. The stripping composition was then heated by bringing a heater heated to 250° C. into close proximity (˜1 mm) of the liquid surface. In this manner, the liquid was heated by convective heating. During heating, the temperature was maintained by varying the separation distance between the heater and the liquid surface to control the liquid temperature to a target temperature. In this case, the target temperature for the stripping composition was 105° C. The total time in which heat was applied to the liquid was 9.5 min. After 9.5 min, the heater was removed. Each wafer was then spun to fling off liquid from the surface of the wafer. To perform this fling-off step, the wafer was accelerated to 150 rpm at 200 rpm/sec followed by a delay of 1 sec. After the 1 sec delay, each wafer was rinsed with deionized water via fan spray nozzles while rotating at 500 rpm for 10 sec. The wafer was then rinsed with a small volume of IPA and finally dried by spinning the wafer at 1500 rpm for 20 sec. After this process, the photoresist was removed from the wafer. Results are summarized in Table 1.
TABLE 1
Formulation Composition
Heating
Resist Removal
Example
(given in wt %)
Time (min)
Results
1
54.7
wt % MEA,
9.5
Resist was
24.5
wt % NMP,
removed
9.95
wt % DMAE,
9.95
wt % MIPA,
0.5
wt % resorcinol,
0.4
wt % H 2 O
MEA = monoethanolamine
NMP = n-methylpyrrolidone
DMAE = dimethylaminoethanol
MIPA = 1-amino-2-propanol
Example 2
Another formulation was investigated for removing 80 μm thick Asahi CX-8040 dry film negative photoresist from a wafer with Sn/Ag alloy solder. Coupon-sized samples of the wafer were processed on a hot plate. Coupons were placed inside a holder with a well with a volume of 2.7 mL. 1.8 mL of formulation was used to cover the coupon, resulting in a thickness of formulation of ˜2 mm on top of the coupon. The holder was placed on the hot plate such that the liquid temperature reached about 108° C. The sample was heated for 3.5 minutes. After heating, the coupon was then removed from the well using tweezers and was rinsed with pressurized water of 45 psi via a fan spray nozzle for 10-20 sec. Finally, the coupon was rinsed with IPA and blown dry with a stream of air. The formulation compositions, heating time, and resist removal results are summarized in the Table 2.
TABLE 2
Formulation composition, heating time, and resist removal result for
Example 2.
Formulation Composition
Heating
Resist Removal
Example
(given in wt %)
Time (min)
Results
2
77
wt % NMP,
3.5
Complete resist
3
wt % MEA,
removal
15.5
wt % propylene glycol,
4
wt % DMDPAH,
0.5
wt % H 2 O
DMDPAH = dimethyldipropylammonium hydroxide
Example 3
Another formulation was investigated for its efficacy for removing 120 μm thick Asahi CX A240 dry film negative photoresist from a 300 mm wafer with Sn/Ag solder pillars. Coupon-sized samples of the wafer were processed on a hot plate. Coupons were placed inside a holder with a well with a volume of 2.7 mL 1.8 mL of formulation was used to cover the coupon, resulting in a thickness of formulation of ˜2 mm on top of the coupon. The holder was placed on the hot plate such that the liquid temperature reached about 110° C. The samples were heated. After heating, the coupon was then removed from the well using tweezers, and was rinsed with pressurized water of 45 psi via a fan spray nozzle for 10-20 sec. Finally, the coupon was rinsed with IPA and blown dry with a stream of air. The formulation composition, heating time, and resist removal results are summarized in the Table 3.
TABLE 3
Formulation composition, heating time, and resist removal result for
Example 3.
Formulation Composition
Heating
Resist Removal
Example
(given in wt %)
Time (min)
Results
3
24.75
wt % CHP,
5.5
Complete resist
9.95
wt % DMAE,
removal
54.75
wt % MEA,
9.95
wt % MIPA,
0.6
wt % H 2 O
CHP = N-cyclohexyl-2-pyrrolidone
Examples 4-5
Formulations with varying compositions were investigated for their efficacy for removing 80 μm thick Asahi CX-8040 dry film negative photoresist from a 300 mm wafer with Pb/Sn alloy solder. Coupon-sized samples of the wafer were processed on a hot plate. Coupons were placed inside a holder with a well with a volume of 2.7 mL. 1.8 mL of formulation was used to cover the coupon, resulting in a thickness of formulation of ˜2 mm on top of the coupon. The holder was placed on the hot plate such that the liquid temperature reached about 115° C. The samples were heated for different times depending on the formulation being tested. After heating, the coupon was then removed from the well using tweezers, was rinsed with pressurized water of 45 psi via a fan spray nozzle for 10-20 sec. Finally, the coupon was rinsed with IPA and blown dry with a stream of air. The formulation compositions, heating time, and resist removal results are summarized in the Table 4.
TABLE 4
Formulation compositions, heating time, and resist removal results
for Examples 4-5
Formulation Composition
Heating
Resist
Example
(given in wt %)
Time (min)
Removal Results
4
85
wt % NMP,
3
Complete resist
3
wt % MEA,
removal
9.3
wt % propylene glycol,
2.4
wt % TMAH,
0.3
wt % H 2 O
5
85
wt % NMP,
3.5
Complete resist
3
wt % DMAE,
removal
9.3
wt % propylene glycol,
2.4
wt % TMAH,
0.3
wt % H 2 O
TMAH = tetramethylammonium hydroxide
Example 6
This example concerns the removal of a 50 μm thick TOK CR4000 positive spin-on photoresist from a 300 mm wafer with Cu pillars and Sn/Ag solder caps. The composition of the stripping composition was 58.6 wt % 1-formylpiperidine, 39.4 wt % aminoethylethanolamine, 1.5 wt % H 2 O, and 0.5 wt % of a corrosion inhibitor, where the corrosion inhibitor is a mixture of dodecanedioic acid, undecanedioic acid, and sebacic acid, which may be sold under the tradename CORFREE M1. The wafer was processed on an EVG-301 RS single wafer photoresist stripping equipment. The wafer was placed in a chuck where ˜96% of the surface area of the backside of the wafer was in contact with air, and the outer diameter of the chuck forms a liquid containment barrier around the perimeter of the wafer. The outer 3 mm radius of the backside of the wafer was in contact with the chuck. This chuck is referred to as the ring chuck. The wafer was covered with 70 mL of the stripping composition. During processing, the stripping composition remained only on the wafer and did not fill the full inner diameter of the chuck. Therefore, the thickness of the stripping composition on top of the wafer was ˜1 mm. The ratio of the thickness of the stripping composition to the thickness of the resist was 20:1. The stripping composition was then heated by bringing a heater at 250° C. into close proximity (˜1 mm) of the liquid surface. In this manner, the liquid was heated by convective heating. During heating, the temperature was maintained by varying the separation distance between the heater and the liquid surface to control the liquid temperature to a target temperature. In this case, the target temperature for the stripping composition was 105° C. The total time in which heat was applied to the liquid was 4 min. After 4 min, the heater was removed. The wafer was then rinsed with deionized water via fan spray nozzles simultaneously while rotating at 500 rpm for 20 sec. The wafer was next rinsed with a small volume of IPA and finally dried by spinning the wafer at 1500 rpm for 20 sec. After this process, the photoresist was completely removed from the wafer.
While applicant's disclosure has been provided with reference to specific embodiments above, it will be understood that modifications and alterations in the embodiments disclosed may be made by those practiced in the art without departing from the spirit and scope of the invention. All such modifications and alterations are intended to be covered. | Compositions are described that are useful for removing organic and organometallic substances from substrates, for example, photoresist wafers. Processes are presented that apply a minimum volume of a composition as a coating to the inorganic substrate whereby sufficient heat is added and the organic or organometallic substances are completely removed by rinsing. The compositions and processes may be suitable for removing and, in some instances, completely dissolving photoresists of the positive and negative varieties, and specifically negative dry film photoresist from electronic devices. | 2 |
FIELD OF THE INVENTION
[0001] The present invention relates to debt collection. More particularly, but not exclusively, the present invention relates to methods and systems for performing legal processing associated with debt collection.
BACKGROUND OF THE INVENTION
[0002] Debt collection has numerous complexities and problems. These complexities may make it difficult for all parties involved in the process including consumers who have incurred the debt, creditors who are owed the debt, agencies who work on behalf of the creditors to collect the debt, and lawyers involved in the debt recovery process. What are needed are better ways to deal with consumer debt collection as it relates to legal collections
SUMMARY OF THE INVENTION
[0003] Therefore it is primary object, feature, or advantage to the present invention to improve over the current state of the art.
[0004] It is a further object, feature, or advantage of the present invention to create client and consumer transparency into and throughout the process of legal recoveries.
[0005] It is another object, feature, or advantage of the present invention to provide a single point of interaction for consumers during the life of the legal process.
[0006] It is another object, feature, or advantage of the present invention to provide a single source system for 100% of the phone calls and processing related to the legal process for debt collection.
[0007] Another object, feature, or advantage of the present invention is to provide completely transparent functionality for all legal accounts.
[0008] Yet another object, feature, or advantage of the present invention is to establish increased levels of control over each step in the process.
[0009] Yet another object, feature, or advantage of the present invention is to increase expense validation.
[0010] Yet another object, feature, or advantage of the present invention is to provide a system with coded rules required for each next step in the process.
[0011] A still further object, feature, or advantage of the present invention is to provide the ability to stop accounts anywhere within the legal recovery process.
[0012] Yet another object, feature, or advantage of the present invention is to eliminate the system of record conflicts and restraints.
[0013] A further object, feature, or advantage of the present invention is to provide a single source for balance calculations, payment, and cost posting.
[0014] Another object, feature, or advantage of the present invention is to provide adaptability to client payment posting (including interest calculations).
[0015] A still further object, feature, or advantage of the present invention is to provide a single point of record for validation of accounts, confirmation of balances, document sources and other information.
[0016] Yet another object, feature, or advantage of the present invention is to provide the opportunity for the clients to gain control over risk
[0017] A still further object, feature, or advantage of the present invention is to provide a client with the ability to directly see, hear, and touch all accounts in any step within the process.
[0018] Yet another object, feature, or advantage of the present invention is to provide for management of state and court level requirements and changes.
[0019] Yet another object, feature, or advantage of the present invention is to establish applicable “scrubs” at each move to invalidate suit process steps.
[0020] A further object, feature, or advantage of the present invention is to allow for consumer interaction points for account viewing.
[0021] Yet another object, feature, or advantage of the present invention is to provide a method by which network attorneys are returned to focus primarily on their training.
[0022] Another object, feature, or advantage of the present invention is to eliminate system of record (SOR) variances.
[0023] A further object, feature, or advantage of the present invention is to allow a debt collection entity to control the entire process so that their regulatory strengths to manage and control the process, and their call center management skills to remove variability may be leveraged.
[0024] One or more of these and/or other objects, features, or advantages of the present invention will become apparent from the specification and claims that follow. No single embodiment need to exhibit each and every object, feature, or advantage of the present invention. It is contemplated that different embodiments may have different objects, features, or advantages.
[0025] According to one aspect, a method for managing legal recoveries is provided. The method includes providing a customer relationship management (CRM) system executing on one or more servers, providing a vendor interface to the CRM system, providing a client interface to the CRM system, wherein the client interface enables clients to send accounts to the CRM system for pre-legal and legal work, monitor performance on the accounts, and review the accounts, providing an attorney interface to the CRM system, wherein the attorney interface provides for receiving the accounts in the legal work flow and reporting on status of the accounts in the legal work flow, and providing a consumer interface to the CRM system, wherein the consumer interface enables a consumer to view and make payments to an account associated with the consumer. The method further includes accepting accounts for legal recovery into the CRM system from one or more clients, applying a pre legal work flow to the accounts for legal recovery in the CRM system, applying a legal decision matrix to determine whether the accounts advance to a legal work flow from the pre legal work flow, and for the accounts which advance to the legal work flow, assigning the accounts to one or more attorneys and communicating information about the accounts through the attorney interface.
[0026] According to another aspect, a system for legal processing is provided. The system includes a customer relationship management (CRM) system wherein the customer relationship management system executes on at least one computing device and is cloud-based. The system further includes a vendor interface to the CRM system, the vendor interface available through the cloud for interacting with the CRM system, wherein the vendor interface enables vendors to perform vendor functions. The system further includes a client interface to the CRM system, the client interface available through the cloud for interacting with the CRM system, wherein the client interface enables clients to perform client functions. The system further includes a consumer interface, the consumer interface available through the cloud for interacting with the CRM system, wherein the consumer interface enables consumers to perform consumer functions. The system is configured for accepting accounts for legal recovery into the CRM system from one or more clients, applying a pre legal work flow to the accounts for legal recovery in the CRM system, and applying a legal decision matrix to determine whether the accounts advance to a legal work flow from the pre legal work flow.
BRIEF DESCRIPTION OF THE DRAWINGS
[0027] FIG. 1 is a block diagram illustrating another example of a system.
[0028] FIG. 2 provides another example of a process flow overview.
[0029] FIG. 3 illustrates another example of a pre-legal work flow.
[0030] FIG. 4 illustrates another example of a legal decision matrix.
[0031] FIG. 5 illustrates another example of a legal work flow.
[0032] FIG. 6 illustrates another example of a case management work flow.
[0033] FIG. 7 illustrates an example of a payment module.
[0034] FIG. 8 illustrates an example of a compliance module.
[0035] FIG. 9 illustrates an example of a non-producing judgment module.
[0036] FIG. 10 illustrates an example of a skip trace module.
[0037] FIG. 11 is a block diagram illustrating another example of a system of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0038] The present invention provides for managing the debt collection process, including where the legal process is used for debt collection. The present invention allows for a systematic and complete management of various phases in order to provide transparency, increased efficiency, and more control over the process.
[0039] FIG. 1 is a block diagram illustrating another embodiment of a system 100 . As shown in FIG. 1 , a computing system 102 provides for model decisions 104 , 0 /S services 106 , CRM processing 108 , and applying an account distribution strategy 110 . The computing system provides for receiving client legal accounts 112 from clients and provides a client interface 114 such as through a cloud-based platform. A consumer interface 116 is also provided. In addition interactions can occur with various vendors including a first attorney 118 , a second attorney 120 , a third attorney 122 , and additional attorneys 124 as shown.
[0040] FIG. 2 provides another example of a process flow overview. The process 200 is shown. In a first step 202 a client places accounts and in step 204 the accounts are loaded into the CRM system. In step 206 the skip trace module is executed for the accounts. The skip tracing may use a waterfall process as described in U.S. patent application Ser. No. 14/026,074 (“cloud based skip tracing”), hereby incorporated by reference in its entirety. Skip tracing may be performed using services from one or more vendors. In step 208 the pre-legal workflow process is executed allowing for a pause if a payment posts. In step 210 collection efforts are performed. In step 212 accounts are updated. In step 214 documents and/or media are processed. In step 216 data elements and media are updated. In step 218 a legal decision matrix is implemented. For accounts that fail, these accounts are returned to the pre-legal workflow 208 . For accounts which pass, these accounts are advanced to the legal work flow process 220 . Then in step 222 , the accounts are assigned to an attorney. In step 224 a suit is filed. If the suit is lost then the process stops in step 226 . If the suit is won then in step 228 a judgment is granted and in step 230 a garnishment is filed. In step 232 a determination is made as to whether the balance is paid. If it is then the process stops in step 226 . If not, then the process continues to the legal work flow 220 . Thus, the process 200 provides for managing collection efforts.
[0041] FIG. 3 illustrates another example of a pre-legal work flow. According to the pre-legal workflow 300 , in step 302 a client places accounts. In step 304 , the accounts are loaded into a CRM system. In step 306 a skip trace module is applied. In step 308 each account is assigned to a collection unit. In step 310 a first notice is sent. In step 312 the accounts may be placed in a collection work list. In step 314 a compliance module subroutine may be executed to ensure compliance. In step 316 account contact efforts may be performed. In step 318 collection strategies may be applied. The collection strategies may include sending the accounts to a dialer and having representatives speak with the debtor. In step 320 , documents and/or media related to the debt may be processed. In step 322 a payment module sub-routine may be executed. If the module fails, the process returns to step 318 . If the module passes, then in step 324 the account or accounts can proceed to the legal decision matrix.
[0042] FIG. 4 illustrates another example of a legal decision matrix 400 . In step 402 accounts are placed from a client. In step 404 accounts are loaded into the CRM system. In step 406 a skip trace module is executed. In step 408 a compliance module sub-routine is executed. In step 410 a determination is made as to whether required data elements are present. If they are then in step 420 a determination is made as to whether documents and/or media needed to support a legal claim are present. If they are then in step 422 a determination is made as to whether a current balance limit has been reached as may be set by a particular state level requirements. If it is then in step 424 a determination is made as to whether a current balance limit is reached as set by the client. If it is then in step 426 a determination is made as to whether the account is in an excluded state. If it is not, then in step 428 a determination is made as to whether the debt owed falls within the statute of limitations. If it does, then the account is then moved to the legal work flow process 430 . If in step 410 required data elements are not present, or in step 420 documents and media is not present, or if in step 422 the current balance limit is not reached for the state, or if in step 424 the current balance limit is not reached for the client, of if in step 426 the account is in an excluded state, or in step 428 the debt owed is not within the statute of limitations then the process proceeds to step 432 where a determination is made as to whether the account was from a pre-legal workflow. If it was not, then in step 434 a determination is made as to how long the account has been placed. If the account has been placed for greater than a threshold number of days then in step 436 the account is returned to the client. If in step 434 the account has not been placed for greater than a threshold number of days, in step 440 the account may be returned to legal work flow. If in step 432 a determination is made that the account came from a pre-legal workflow then in step 438 the account may be returned to the pre-legal workflow.
[0043] FIG. 5 illustrates another example of a legal work flow. In the process 500 , in step 502 one or more accounts are received from the legal decision matrix. In step 504 the accounts are assigned to an attorney collection unit. In step 506 a skip trace module may be executed. In step 508 a first notice may be sent. In step 510 accounts are placed in an attorney pre-legal work list. In step 512 a compliance module sub routine may be executed. In step 514 account contact efforts are implemented. In step 516 collection strategies are applied. In step 518 a payment, promise, mail return, compliance (PPMC) module subroutine is executed. The PPMC module is used to track payments, promises to make payments, mail returns, and compliance including compliance with promise to make payments. In step 520 documents are received. In step 522 a law suit is prepared. In step 524 suit collection strategies are applied. In step 526 a PPMC module sub-routine is executed. In step 528 a suit is filed. In step 530 a determination is made as to whether or not there was an answer. If not, then the process proceeds to a judgment in step 532 . If there is an answer then in step 546 the answer can be evaluated to determine if there are counterclaims, if there will be a trial, if witnesses are need and in step 540 the process proceeds for case management. Returning to step 532 after there is a judgment, in step 534 judgment collection strategies may be applied. In step 536 a PPMC module sub-routine may be executed. In step 538 post judgment execution is performed. In step 540 a PPMC module sub routine may be executed. In step 542 a non-producing judgment module sub routine may be executed.
[0044] FIG. 6 illustrates another example of a case management work flow. The process 600 begins in step 601 from the legal work flow. In step 602 a determination is made as to whether counter claims were filed, a trial is needed, or there is a request for a witness. If there is a counterclaim then in step 604 a counterclaim has been filed and so in step 606 appropriate notes are entered in the CRM system. In step 608 the appropriate court date is calendared. In step 610 the counterclaim defendant is determined. If the counterclaim defendant is the client then in step 612 the client is notified and a compliance department is notified. In step 614 the process may be paused to allow time for compliance and the client to become involved. Returning to step 610 if a determination is made that the counterclaim defendant is the servicer, then in step 616 the compliance department and compliance may be notified. Returning to step 602 if the case is to proceed to trial, in step 618 notes may be entered on the CRM system and in step 620 a hearing date may be calendared. Returning to step 602 if there are witnesses, then in step 622 notes including the witnesses needed may be entered on the CRM system. Then in step 624 the court date may be calendared and in step 626 the client is notified of the request for a witness.
[0045] FIG. 7 illustrates an example of operation of a payment module 700 . In step 702 an account enters the sub routine. In step 704 a determination is made as to how long the account has been placed. This determination may take into account the length of time the account has been placed in pre-legal workflow or the length of time the account has been placed in legal workflow. For example, if the account has been place for greater than a threshold number of days in pre-legal workflow (or legal work flow), the process proceeds to step 708 . If the account has not been placed for a sufficient amount of time, then the process proceeds to step 706 back to the appropriate collection step. If in step 704 a determination is made that the account has been placed for the appropriate number of days, then in step 708 a determination is made as to whether a payment has made within a threshold number of days. If it has, then in step 724 a determination is made as to whether the payment was payment in full. If it was then the account is returned to the client in step 722 . If there is a payment, but it is not payment in full, then in step 726 a determination is made as to whether the account has been settled. If it has, then in step 728 the account returns to the client. If not, then in step 730 the process returns to the preceding collection step. Returning to step 708 , if no payment is made within the given time period, then in step 710 a determination is made as to whether there is an existing promise to pay within the given time period. If there is, then in step 712 the process returns to a preceding collection step. If not, then in step 714 a determination is made as to whether there is a mail return flag indicating that mail has been returned. If there is, then in step 716 the process returns to the preceding collection step. If not, then in step 718 compliance validation occurs and if passed, in step 720 the process returns.
[0046] FIG. 8 illustrates an example of a compliance module 800 . In step 802 , the process is invoked from a PPMC, pre-legal workflow, or legal workflow. In step 804 a determination is made as to whether the number of days remaining in the statute of limitations (SOL) is greater than a threshold number of days. If it is not, then in step 806 the process returns to the preceding collection step. If it is, then in step 808 a determination is made as to whether the Social Security Income (SSI) or the Servicemembers Civil Relief Act (SCRA) classification is valid. If it is, then in step 810 the process returns to the preceding collection step. If it is not, then in step 812 a determination is made as to whether there is a bankruptcy or whether the debt involves a deceased individual, fraud is alleged, or there is a dispute as to amount. If it is then in step 814 the account is returned to the client. If not, then in step 816 the process returns to normal activity.
[0047] FIG. 9 illustrates an example of a non-producing judgment module 900 . In step 902 an account enters the sub routine. In step 904 a determination is made as to whether there is a judgment. If not, then in step 906 a determination is made as to whether a suit has been filed. If not, then in step 908 the account returns to the attorney pre-legal work list. If there is a suit filed then in step 910 the process returns to suit collection strategies. Returning to step 904 if there is a judgment then in step 912 a determination is made as to whether the difference between the current date and the judgment date is greater than a threshold. If not, then in step 914 the process returns to the preceding collection step. If it is, then in step 916 a determination is made as to whether the difference between the current date and the last payment date is greater than a threshold or null. If not, then in step 918 the process returns to the preceding collection step. If it is, then in step 920 the status in the CRM system is populated to reflect a non-producing judgment. Then in step 922 , the account is sent to an attorney non-producing judgment unit. In step 924 a skip trace module is executed. In step 926 accounts are placed in the attorney non-producing judgment work list. In step 928 the compliance module sub routine is executed. In step 930 account contact efforts are performed. In step 932 non-producing judgment strategies are applied. In step 934 a determination is made as to whether post judgment execution is available. If not, then in step 936 the account is returned to the attorney non-producing judgment collection unit. If execution is available, then in step 938 the process returns to the legal work flow post judgment execution.
[0048] FIG. 10 illustrates an example of a skip trace module 1000 . In step 1002 an account enters the skip trace module. In step 1004 one or more skip trace vendors are used to find a consumer owing debt. In step 1006 a real estate and place of employment (POE) vendor is used. In step 1008 the account is scored. In step 1010 a determination is made as to whether new data elements are applied to the accounts. In step 1012 the skip trace module is completed and the process returns to its previous activity.
[0049] FIG. 11 is a block diagram illustrating a system 1200 . As shown in the system 1200 there is a consumer 1202 . The consumer can interact with a call center 1203 which may include a dialer 1205 . The call center 1203 may be operatively connected to one or more servers 1204 . Thus, one or more dialers may be integrated with a CRM system. The dialer(s) may be used for placing calls or routing inbound calls. Account records 1206 may be stored in a database operatively connected to the server(s) 1204 associated with a CRM system. Various different user interfaces are also provided. These include a network attorney interface 1210 which is an example of a vendor interface, a consumer interface 1212 , and a client interface 1214 .
[0050] The invention allows for a comprehensive system and methodology which allows for one entity such as a debt collection agency to manage the debt collection process in an efficient and effective manner. Because a single system and integrated methodology is used, the status of a given account can be readily determined at any point in time. This is a significant advantage, especially with respect to those accounts which have been referred out to attorneys for collections. In addition, because an integrated system is used workflows can be controlled to ensure efficiency and transparency throughout the process.
[0051] As previously explained, the system may be a cloud-based server which executes on a server. The server may be a virtual server or physical server and may be distributed across multiple machines to provide services such as those described herein. The server may be programmed in software to perform the functions described, with instruction sets executing on the server performing the functionality described. The instructions as well as data may be stored on non-transitory computer readable storage media.
[0052] Therefore, various embodiments have been showing related to systems, methods, and apparatus associated with debt collection. Although specific examples are shown, the present invention should not be limited to these specific examples as various options and alternatives are contemplated such as may be appropriate in particular circumstances. | A method includes providing a customer relationship management (CRM) system executing on one or more servers, providing a vendor interface to the CRM system, providing a client interface to the CRM system, wherein the client interface enables clients to send accounts to the CRM system for pre-legal and legal work, monitor performance on the accounts, and review the accounts, providing an attorney interface to the CRM system, wherein the attorney interface provides for receiving the accounts in the legal work flow and reporting on status of the accounts in the legal work flow, and providing a consumer interface to the CRM system, wherein the consumer interface enables a consumer to view and make payments to an account associated with the consumer. Whereas, all parts are managed by one entity instead of several across various platforms and structures. | 6 |
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The field of the invention relates to data processing and in particular to the processing of speculative transaction requests.
[0003] 2. Description of the Prior Art
[0004] It is known in the prior art to generate speculative transaction requests to improve the performance of a system. For example, there may be branch prediction logic associated with a processor which predicts which way a branch in an instruction stream may go and performs the prefetching of instructions and/or the loading of required data into the cache for the predicted branch before the branch has actually been taken. Thus, if the prediction is correct, the time needed to perform the instructions within the branch is significantly reduced, whereas if the prediction is not correct then the preloaded instructions and data are not required and the power and resources used to perform these “speculative” steps have in effect been wasted.
[0005] Performing speculative transactions can significantly increase the performance of a system, however, they can also cause additional loading to that system and may also increase power consumption.
[0006] In some processors such as Cortex-R4 developed by ARM® (of Cambridge UK) it is known for a master that generates a speculative read to drop this read, i.e. not send the request, if it decides that the bus it is to use is busy or the memory too slow. It can only judge the activity of the system from its own transaction requests, it knows nothing of the activity of other masters in the system.
[0007] It would be advantageous to be able to control the processing of speculative requests such that they can be performed where an increase in performance can be achieved and is desirable, but can be avoided where additional processing is not desirable.
SUMMARY OF THE INVENTION
[0008] A first aspect of the present invention provides circuitry for receiving transaction requests from a plurality of masters, said circuitry comprising: a port for receiving said transaction requests, at least one of said transaction requests received comprising an indicator indicating if said transaction is a speculative transaction; a port for outputting a response to said master said transaction request was received from; and transaction control circuitry; wherein said transaction control circuitry is responsive to a speculative transaction request to determine a state of at least a portion of a data processing apparatus said circuitry is operating within and in response to said state being a predetermined state said transaction control circuitry generates a transaction cancel indicator and outputs said transaction cancel indicator as said response, said transaction cancel indicator indicating to said master that said speculative transaction will not be performed.
[0009] Although the performance of speculative transactions can significantly increase performance they can also increase power consumption and resource loading. Their usefulness is dependent to some extent on the operating state of the data processing apparatus. Realising this and using the state of the data processing apparatus as a factor when determining whether or not to cancel a speculative transaction can be advantageous.
[0010] Although it is known for a master not to generate speculative transaction requests when it exceeds a certain number of pending non-speculative requests, more centralised control of speculative transactions has not previously been available. One reason for this is that it is not generally possible for a device receiving a transaction request from a master to know that that request is speculative. Furthermore, if the transaction requested is to not to be performed then the master should be made aware of this otherwise the master will continuously be waiting for the pending transaction to complete. This information is transmitted to the master in the form of an abort response, however the master does not need to do any error handling code in response to the abort response, it simply deletes the information in the bus interface unit indicating that this transaction is pending. Thus, a dynamic decision making technique is disclosed that allows speculative transactions to be cancelled or performed on a case by case basis depending on a state of the data a processing apparatus.
[0011] The present invention therefore addresses the problems of the prior art by providing circuitry that can not only recognise speculative transaction requests but can also cancel them in dependence upon the state the data processing apparatus is in. Thus, it can determine when the operating state of the system is such that the processing of speculative transactions would be desirable and can in such cases allow them to be processed. It can also determine states where it would not be desirable to process the transactions and in such cases it can act to cancel them. It can then transmit the information that the request has been cancelled to the master that sent the original request and thereby avoid problems associated with indefinitely pending transactions at the master. Thus, the performance of the system can be tailored to its operating state by the provision of an additional control mechanism for cancelling speculative transactions.
[0012] In some embodiments, said predetermined state is a low power state.
[0013] A data processing apparatus may operate in several different power states, for example, a high power state such as mains, lower power states such as full battery, half battery or low battery, or a lower power state where maximum performance is not required (for example for a mobile phone in standby mode rather than running a game). Thus, in a high power state performance is all important whereas in one or more lower power states conservation of energy becomes important. As noted previously, speculative transactions can increase the performance of an apparatus and as such in a high power mode it is advantageous to perform them, while in one or more of the lower power modes where power conservation is more important it may be advantageous not to perform speculative transactions and cancel them when they are requested.
[0014] In some embodiments, said circuitry comprises a register for storing a low power indicator, said circuitry determining said state of said data processing apparatus in response to a value stored in said register.
[0015] The circuitry may determine the power state of the data processing apparatus in a number of ways but in some ways it is determined from a low power indicator stored in a register within the circuitry.
[0016] In other embodiments, said circuitry comprises an input from a power controller said input being adapted to receive a signal indicating a power state of said data processing apparatus, said circuitry determining said state of said data processing apparatus in response to said power state signal received from said power controller.
[0017] In some embodiments, said predetermined state is a busy state.
[0018] Alternatively or additionally to the predetermined state being a power state of the device, it may also be a state indicating how busy the device is. If the device is very busy such that there is not much resource available then it may be more advantageous to cancel speculative transactions rather than adding them to what are already very long queues.
[0019] In some embodiments said predetermined state is dependent upon a power state of said circuitry and an activity state of said circuitry, said circuitry comprising a plurality of power states and a plurality of activity states, said predetermined state comprising a low power state, a high activity state and a combination of a lower power state and a higher activity state.
[0020] The circuitry may have a number of power states and activity states and the predetermined state where speculative transaction are cancelled may depend on a combination of these states. Thus, the predetermined state may be one of the very low power states, one of the very busy states or a combination of one of the lower power states and one of the higher activity states. Thus, where the circuitry is quite busy and wishes to conserve power, it may be advantageous to cancel the speculative transactions.
[0021] In some embodiments, said circuitry comprises an interconnect, while in other embodiments, said circuitry comprises a memory controller.
[0022] One advantage of the circuitry comprising an interconnect is that the cancellation of the speculative transaction is determined within the interconnect which avoids the need to broadcast the transaction request and the cancellation indicator further than this interconnect, thereby potentially saving power.
[0023] In some embodiments, said memory controller comprises a pending queue of pending transactions, said data processing apparatus being in said busy state when said queue comprises at least one of more than a predetermined number of transactions and more than a further predetermined number of non-speculative transactions in said pending queue.
[0024] Although, the busy state of the data processing apparatus can be determined in a number of ways, in some embodiment it is determined in dependence upon the length of a pending queue within the memory control circuitry. The length of the pending queue may be determined from the number of all the transactions pending in the queue or it may be the number of non-speculative transactions in the queue that is used or it may be both of these. In other embodiments, the activity state of the data processing apparatus may be determined from circuitry that monitors a bus's activity.
[0025] In some embodiments, in response to said state not being said predetermined state said memory controller provides said speculative transaction request with a low priority status and puts said transaction in said pending queue in a position dependent upon its priority and in response to said state changing to said predetermined state while said speculative request is still in said queue, said memory controller cancels said transaction and generates said transaction cancel indicator and outputs said transaction cancel indicator to said master.
[0026] If the data processor is not within the predetermined state when it receives a speculative transaction request then in some embodiments the memory controller provides the speculative transaction request with a low priority status and inserts it in the pending queue at a point dependent upon this low priority status. It should be noted that the pending queue contains a list of transactions stored in the “queue” in the order they are to be performed. Transactions therefore join the “queue” at different points depending on their priority status. A transaction may stay in the pending queue for some while, particularly if higher priority transactions are generated while it is in the queue. Furthermore, in some embodiments a transaction may be deleted from the queue if it is determined that it has been in the queue for longer than a predetermined amount of time. Thus, if the state of the data processing apparatus changes to the predetermined state, for example it enters low power mode, while this speculative request is still in the queue then the memory controller cancels the transaction and generates a transaction cancel indicator. Thus, in some embodiments in addition to cancelling the transaction request if it is generated when the data processing apparatus is in a predetermined state, it may also be cancelled later if the data processing apparatus enters the predetermined state while the transaction is still pending.
[0027] In some embodiments, said memory controller is responsive to said speculative transaction request and to said state being said predetermined state to open a row in said memory comprising an address to be accessed by said speculative transaction request and to cancel said transaction and to generate said transaction cancel indicator.
[0028] Although, the speculative transaction requests may just be cancelled, in some embodiments in response to the data processing apparatus being in the predetermined state, in other embodiments a compromise of opening a row in the memory that the transaction was to access is performed and the transaction request is cancelled. Thus, not all of the power required or the resources needed are used to perform the transaction, however, some are used such that the row is open and thus, if the speculative transaction becomes a true transaction and is later generated, the row will be open and the performance of the transaction is improved.
[0029] A further aspect of the present invention provides a master for generating speculative and non-speculative transaction requests and for generating a speculative indicator to indicate requests that are speculative, said master comprising a bus interface unit and an output port for outputting said requests, said speculative requests being output with said speculative indicator, said master comprising a port for receiving a response to said requests, said master being responsive to a response indicating said speculative request has been cancelled to delete said data relating to said cancelled transaction request from said bus interface unit.
[0030] In some embodiments, said speculative indicator is output from said master as part of a field identifying said master.
[0031] Although the speculative indicator can be output in a number of forms, in some embodiments it is output as part of a field identifying the master. This can have advantages when prioritizing the order that transactions are to be performed. Generally transactions from a same master are prioritized in the order that they are received, in other words, there is no re-ordering of transactions from the same master. If speculative transaction requests are given a particular master field then they are not bound by the same ordering requirements as other transaction requests from that master and as such they can be given a very low priority.
[0032] A yet further aspect of the present invention provides a data processing apparatus comprising at least one master according to a further aspect of the invention, circuitry according to a first aspect of the present invention and an interface connecting said at least one master and said circuitry.
[0033] In some embodiments the transaction cancel indicator comprises a predetermined encoding transmitted via said interface for example as a unique response bus encoding, while in other embodiments said interface comprises at least one sideband signal line for communicating said transaction cancel indicator to said at least one master.
[0034] It may be that there are not enough signal lines on the interface to provide new encodings to indicate this new information and in which case a new sideband signal line is provided in the interface such as a signal can be sent.
[0035] Furthermore, in some embodiments said interface comprises a further sideband signal line for communicating said speculative transaction indicator as a sideband signal to said transaction request.
[0036] A still further aspect of the invention provides a method of controlling the processing of speculative transactions comprising the steps of:
[0037] generating a speculative transaction request;
[0038] transmitting said transaction request along with an indicator indicating that said transaction request is speculative;
[0039] receiving said transaction request and said indicator;
[0040] determining a state of a data processing apparatus for processing said transaction; and
[0041] in response to said state being a predetermined state generating a transaction cancel indicator and outputting said transaction cancel indicator as a response to said transaction; and
[0042] in response to said state not being said predetermined state performing said transaction and outputting a result of said transaction.
[0043] The above, and other objects, features and advantages of this invention will be apparent from the following detailed description of illustrative embodiments which is to be read in connection with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0044] FIG. 1 shows a data processing apparatus comprising a plurality of masters, an interconnect a memory controller and a memory according to an embodiment of the present invention;
[0045] FIG. 2 shows a data processing apparatus according to a further embodiment of the present invention;
[0046] FIG. 3 shows a flow diagram indicating the steps performed by a memory controller according to an embodiment of the present invention;
[0047] FIG. 4 shows a flow diagram indicating the steps performed by an interconnect and memory controller according to an embodiment of the present invention; and
[0048] FIG. 5 shows a flow diagram indicating the steps performed by a master according to an embodiment of the present invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0049] FIG. 1 shows a data processing apparatus 5 according to an embodiment of the present invention. Data processing apparatus 5 comprises a number of masters 10 , 12 , 14 , 16 such as processors, accelerators, DMA controllers, video or LCD controllers or DSPs which generate transaction requests and transmit them via interfaces 20 , 22 , 24 , 26 to interconnect 30 . Interconnect 30 then receives these transaction requests at ports 32 , 34 , 36 and 38 and transmits them to memory controller 50 which accesses memory 60 . Each master 10 , 12 , 14 , 16 can generate non-speculative transaction requests and at least some of them can generate speculative transaction requests. These speculative transaction requests might be generated by prefetch logic with branch prediction within the master or they might be generated by some sort of prediction logic within a bus interface unit on the master. A master that can generate speculative transaction requests will transmit an indicator along with the request indicating whether the transaction request is a speculative transaction request or not. This information may be sent as a sideband signal to the transaction request on the interfaces 20 , 22 , 24 , 26 or it can be sent as part of the master identifier that identifies each master. Interconnect 30 receives at one of its ports 32 , 34 , 36 , 38 the transaction request and transmits it along with the master identifier and information relating to the port it was received at to memory controller 50 via port 42 and interface 44 . The additional information relating to whether or not the instruction is speculative, which may be sent as a sideband signal or may be part of the master identifier or some other encoding is also sent to memory controller 50 over interface 44 .
[0050] Memory controller 50 comprises control circuitry 52 for controlling the processing of speculative transactions. This control circuitry 52 recognises if a transaction request is a speculative transaction and if it is determines whether the processing apparatus is in a low power or high power state. This can be determined from a value stored in register 54 which is updated with information sent from power controller 70 .
[0051] If circuitry 52 determines that the processing apparatus 5 is in a low power state then when a speculative instruction is received it cancels this transaction and sends information relating to it being cancelled back to interconnect 30 over bus 44 . This information is sent along with the master identifier such that the interconnect can then route this information back to the appropriate master. The pending transaction information that is stored in the bus interface unit of the master is then deleted for that transaction and this stops the bus interface unit from clogging up.
[0052] If register 54 shows that the data processing apparatus 5 is in a high power mode then the speculative transaction is sent to priority logic 56 where it is given a certain priority and is sent via re-ordering logic 58 to pending queue 55 . As it is a speculative instruction it is given a very low priority and thus generally joins the back of the queue. Later transactions that are generated and have a higher priority than a speculative transaction will join the queue ahead of these transactions.
[0053] The memory controller 50 can be configured to respond to a switch from high power mode to low power mode to look at the transactions pending in the queue and in response to detecting any with the lowest priority which would indicate that they were speculative transactions, it can delete these speculative transactions from the queue and generate a transaction cancel indicator to send via interconnect 30 to the master that generated the transaction such that the pending transaction information relating to that transaction in the bus interface unit can be deleted.
[0054] With regard to the re-ordering logic 58 the pending queue is generally ordered in response to the priority of the transactions. Different masters may have different priorities and as such the master identifier field may be used by the priority logic to generate a priority. Furthermore, transactions from a particular master are generally processed in order. If the speculative transaction is given its own master identifier field that identifies both the master and the fact that it is a speculative instruction then it can be provided with the lowest priority and it is not constrained to follow the ordering of the other non-speculative transactions received from that particular master as it has a different master identifier.
[0055] FIG. 2 shows an alternative embodiment of the present invention where the transaction control circuitry 52 is provided within interconnect 30 . Interconnect 30 also comprises a register 34 for holding a value indicating the power state of the processing apparatus and a value indicating how busy the data processing apparatus is. In some embodiments, the speculative transactions are treated in different ways depending both on the power state of the data processing apparatus and on how busy it is. Thus, if the data processing apparatus is busy and/or in a low power state speculative transactions are cancelled whereas if it is in a high power state and is not busy then they are processed. In this embodiment, register 34 has an indicator indicating if the processing apparatus is in low power mode and a further indicator indicating the activity of the processing apparatus 5 . It should be noted that in this embodiment there are only two power states and two activity states and thus, a single value for each in register 34 can indicate these states. In other embodiments there may be several power states and several activity states in which case, the register 34 would have several indicator bits for the power states and for the activity states. In such an embodiment speculative transactions would be cancelled in response to a very busy state, a very low power mode, or a combination of a fairly busy state and lower power mode.
[0056] In this embodiment, the activity is determined in response to the length of pending queue 55 within memory controller 50 . Thus, a signal is sent from the memory controller when the pending queue exceeds a certain length and a further signal is sent when it falls below this length. This signal acts to set the “busy” value in register 34 . In other embodiments where interconnects track outstanding transactions, the busy signal may be generated inside the interconnect.
[0057] In this apparatus the information that the transaction request is speculative is sent as a sideband signal to the transaction request from the master to the interconnect. The control circuitry 30 responds to this sideband signal to cancel the transaction if it is speculative and the system is in low power or busy mode. It does this by sending a response to the master indicating that the transaction will not be processed. By cancelling the transaction in the interconnect, it is not broadcast all the way to the memory controller which may help to reduce power consumption. In some embodiments in addition to cancelling the transaction it opens the row in the memory that the data access transaction was addressing although it does not perform the rest of the transaction. This means that if the speculative transaction is later performed as a non-speculative transaction the row may already be open.
[0058] In response to the system being in high power or non-busy mode, the speculative transaction is forwarded to the memory controller via interconnect 40 . A sideband signal may be added to it to indicate that it is speculative and this allows priority logic 56 and reordering logic 58 to give it a very low priority so that it joins the back of the queue.
[0059] It should be noted that in alternative embodiments, the interconnect and memory controller may be a single unit with the speculative instruction control circuitry being provided within this single unit.
[0060] FIG. 3 shows a flow diagram indicating the steps performed by a memory controller according to an embodiment of the present invention. Initially a transaction request is received from a master. It is then determined if the request is speculative or not. If it is not the transaction is performed and the result of the transaction is sent back to the master. If it is determined that it is speculative then it is determined if the system is in a low power mode or not. If it is not then as in the case of a non-speculative request the transaction is performed. If it is in a low power mode the transaction is cancelled and a response indicating the transaction to be cancelled is sent to the master.
[0061] FIG. 4 shows an alternative embodiment of a method according to an embodiment of the present invention. In this embodiment, the transaction request for the master is received at an interconnect and determination is made to see if it is speculative or not. If it is then a request is transmitted to the memory controller with an identifier field identifying the master and identifying the request as speculative. It is then determined if the system is in a busy state or in a low power mode. If it is in either of these then the transaction is cancelled and a response indicating this is sent to the master. If the request is not speculative then the request is transmitted to the memory controller with an identifier field identifying the master. At this point the priority of the received transaction is set based on the master identifying field. Similarly if the system is not busy and in a high power mode then the speculative instruction that is sent to the memory controller also has its priority set at this point. In this case, the lowest priority will be given to this request as it is a speculative request.
[0062] The requests then sit in a pending queue in their priority order and while they are in the pending queue it is determined if the system switches from a high power non-busy state to a busy state or to a low power mode. In response to detecting that it switches to one of these states the queue is analysed to see if it is longer than a predetermined length and if it is then the excess pending transactions with the lowest priority are cancelled to bring the queue down to the required length. A response to the master is sent indicating that these pending instructions have been cancelled. If the system does not switch while they are in the pending queue then the transactions are executed and the result is returned to the master. Alternatively, in some embodiments on switching to one of these states rather than cancelling pending instructions to produce a queue of a certain length, all of the pending transactions that have the lowest priority and are therefore speculative, are cancelled.
[0063] FIG. 5 shows a flow diagram indicating steps performed by a master. The master generates a speculative transaction and this is output along with a transaction indicator indicating that the transaction is speculative. The master then waits for a response to the transaction. In response to a response to the transaction which may be either that the transaction is completed or that it has been deleted the pending transaction information relating to that transaction that is stored in the bus interface unit is deleted.
[0064] Although illustrative embodiments of the invention have been described in detail herein with reference to the accompanying drawings, it is to be understood that the invention is not limited to those precise embodiments, and that various changes and modifications can be effected therein by one skilled in the art without departing from the scope and spirit of the invention as defined by the appended claims. | Circuitry for receiving transaction requests from a plurality of masters and the masters themselves are disclosed. The circuitry comprises: an input port for receiving said transaction requests, at least one of said transaction requests received comprising an indicator indicating if said transaction is a speculative transaction; an output port for outputting a response to said master said transaction request was received from; and transaction control circuitry; wherein said transaction control circuitry is responsive to a speculative transaction request to determine a state of at least a portion of a data processing apparatus said circuitry is operating within and in response to said state being a predetermined state said transaction control circuitry generates a transaction cancel indicator and outputs said transaction cancel indicator as said response, said transaction cancel indicator indicating to said master that said speculative transaction will not be performed. | 6 |
RELATED APPLICATIONS
This application claims the benefit of priority to U.S. Provisional Patent Application Ser. No. 61/800,838 filed Mar. 15, 2013, entitled “Relocatable Habitat Unit”, and currently co-pending.
FIELD OF THE INVENTION
The present invention pertains generally to Relocatable Habitat Units (RHUs) for use in simulating an environment for a military combat training scenario. More particularly, the present invention pertains to an RHU that can be assembled and disassembled on-site, using panels that can be maneuvered, positioned and interconnected by no more than two men. The Present invention is particularly, but not exclusively, useful as a system and method for the complete assembly of an RHU using only a single hand-operated tool.
BACKGROUND OF THE INVENTION
Military training must necessarily be conducted in an environment that will simulate anticipated combat operations as accurately as possible. For a comprehensive training program, this requires the ability and flexibility to relocate and set-up several different types of training environments. In general, training sites may need to selectively simulate either an urban, suburban, or an open terrain environment.
For a training site, the realism that can be attained when simulating a particular environment can be clearly enhanced by introducing indigenous persons (i.e. actors) into the training scenario. In addition to the indigenous persons, urban and suburban environments can be even more realistic when trainees are confronted by obstacles, such as buildings (e.g. habitats). In most instances, such structures can be relatively modest. Nevertheless, their integration into the training scenario requires planning.
Providing realistic buildings for a training environment requires the collective consideration of several factors. For one, the buildings need to present a visual perception accurate for the particular training scenario. Stated differently, they need to “look the part.” For another, it is desirable that structures assembled on the training site be capable of relatively easy disassembly for relocation to another training site and subsequent use. The use of state-of-the-art movie industry special effects, role players, proprietary techniques, training scenarios, facilities, mobile structures, sets, props, and equipment, all contribute to the Hyper-Realistic™ training model and serve to increase the quality of training.
For military mountain locations such as the Marine Corps Mountain Warfare Center, near Bridgeport, Calif., the 8,000 feet elevation is accessible only by four-wheel drive vehicles. Some mountains, such as those in Fort Irwin, Calif., are accessible only by helicopter. Additionally, only non-permanent structures may be placed on the Marine Corps Mountain Warfare Center due to regulations, the nature of the military compound, and the environment. With this last point in mind, the ability to easily transport, assemble, and disassemble a building used as a training aide is a key consideration.
Heretofore, military combat training scenarios have been conducted either on open terrain, or at locations where there were pre-existing buildings or structures. The alternative has been to bring prefabricated components of buildings to a training site and then assemble the components to create the building. Typically, this has required special equipment, considerable man-hours of labor, and sometimes even requiring the assistance of Military Construction Units (MILCON); requiring significant military financial resources to erect and disassemble such “non-permanent” structures.
In light of the above, it would be advantageous to provide a training environment which can utilize the Hyper-Realistic™ combat environment at any on-site location in a variety of complex, tactically challenging configurations. It would be further advantageous to provide a training environment where the structures are field-repairable. This allows realistic visual feedback to trainees during live fire field exercise, while still allowing multiple training runs without the need to replace training structures.
It is an object of the present invention to provide a repairable construction set and method for assembling and disassembling an RHU in a variety of configurations, at a training site, with as few as two persons. Alternatively, it is an object of the present invention to provide a repairable non-permanent construction set, having the ability of off-site assembly for air transport to facilitate training in remote locations or at high altitudes for specialized military training without the need for MILCON. Still another object of the present invention is to provide a construction set that requires the use of only a single, hand operated tool for the assembly and disassembly of an entire RHU. Yet another object of the present invention is to provide a construction set for the assembly and disassembly of an entire RHU that is relatively simple to manufacture, extremely simple to use, and comparatively cost effective.
SUMMARY OF THE INVENTION
The Relocatable Habitat Unit (RHU) of the present invention is assembled using a plurality of substantially flat panels, designed to be modular, scalable, reconfigurable, and relocatable.
The RHU is based on a lightweight 4′×8′ composite material panel system and engineered to assemble into multi-story, complex configurations with a single tool. The RHU panels are constructed with pultruded fiberglass reinforced plastic beams, bonded with wood, composite, or expanded polystyrene foam panels that are laser cut to replicate the look and texture of various building materials like brick, adobe, mud, wood, bamboo, straw, thatch, etc., sprayed with one-eighth inch of a fire retardant pro-bond and “sceniced” (Pronounced SEE-nicked; a movie industry term that means “aged” to look weathered). Materials and construction provide all-weather, long-lasting, fire-retardant structures suitable for year-round military training in all environments.
In a preferred embodiment, any interior or exterior panel can be interchanged. Common amenities such as windows, doors, stairs, etc. can be attached or installed to the RHU structure. Additionally, a variation of these modular panels can also be used to clad other structures, such as containers, wooden temporary structures, or permanent buildings. For this assembly operation, each panel includes male (M) and female (F) lock connectors. Specifically, these connectors are located along the periphery of each panel. Importantly, all of the (M) connectors can be engaged with a respective (F) connector using the same tool. Thus, an entire RHU can be assembled and disassembled in this manner. Further, each panel is sufficiently lightweight in order to be moved and positioned by one person. As a practical matter, a second person may be required to use the tool and activate the connectors as a panel is being held in place by the other person.
In detail, a construction set for use with the present invention includes a plurality of panels and only the one tool. Each panel has a periphery that is defined by a left side edge, a right side edge, a top edge, and a bottom edge. However, selected panels can have different configurations that include a door or a window. Still others may simply be a solid panel. In particular, solid panels are used for the floor and ceiling (roof) of the RHU. Furthermore, a panel can be omitted, leaving a void to facilitate an entry or exit to a higher or lower level when the RHU is utilized in the multi-story configuration. Each panel, regardless of its configuration, will include at least one (M) connector and at least one (F) connector that are located on its periphery.
In addition to the wall, floor, and ceiling panels, an embodiment of the construction set also includes corner connections and ceiling attachments. Specifically, corner connections are used to engage wall panels to each other at the corners of the RHU. The ceiling attachments, on the other hand, allow engagement of roof panels with the top edges of wall panels and can also be used to stack multiple levels of a RHU, creating complex multi-level urban structure designs. In the multi-level configuration, vertical corner posts and horizontal beams provide a similar function to the corner connections and ceiling attachments, and are used to construct a frame to support a plurality of panels.
The placement and location of male (M) and female (F) lock connectors on various panels of the construction set is important. Specifically, along the right side edge of each wall panel, between its top edge and bottom edge, the lock configuration is (FMMF). Along its left side edge, the lock configuration is (MFFM). Further, along the top edge the lock configuration is (MM), and along the bottom edge it is (M) or (F), depending on the connector of the floor panel.
Unlike the panels, the corner connections are elongated members with two surfaces that are oriented at a right angle to each other. The lock configurations for a corner connection are (F--F) along one surface and (-FF-) along the other surface. Like the corner connections, the ceiling attachments also present two surfaces that are at a right angle to each other. However, their purpose is different and, accordingly, they have a (FF) lock configuration on one surface for engagement with the top edge of a wall panel. They also have either a (MM) or a (FF) configuration along the other surface for connection with a ceiling panel.
Importantly, in addition to the above mentioned panels, connections, and attachments, the construction set of the present invention includes a single hand tool. Specifically, this hand tool is used for activating the various male (M) connectors for engagement with a female (F) connector, in addition to driving other required hardware. For the present invention, this tool preferably includes a hex head socket, a drive that holds the hex head socket, and a ratchet handle that is swivel-attached to the drive.
For assembly of the RHU, the first task is to establish a substantially flat floor. This is done by engaging male (M) connectors on a plurality of floor panels with female (F) connectors on other floor panels. The floor is then leveled using extensions that can be attached to the floor panels at each corner. Next, a wall is erected around the floor of the RHU by engaging a male (M) connector on the right side edge of a respective wall panel with a female (F) connector on the left side edge of an adjacent wall panel. Recall, the lock configurations on the left and right edges of wall panels are, respectively, (FMMF) and (MFFM). Additionally, the bottom edge of each panel in the wall is engaged to the floor using mutually compatible male (M) and female (F) connectors. Finally, the ceiling assembly of the RHU is created by engaging male (M) connectors on ceiling panels with female (F) connectors on other ceiling panels. The ceiling attachments are then engaged to the assembled ceiling. In turn, the ceiling attachments are engaged to the top edge of a wall panel using mutually compatible male (M) and female (F) connectors. All connections for the assembly of the RHU are thus accomplished using the same tool.
In a preferred embodiment all panels are interchangeable. A frame is constructed consisting of vertical corner posts and horizontal beams (analogous to the corner connections and ceiling attachments), each formed with M and F lock connectors along their length that complement the lock connectors on the panels. Once the frame is in place, the panels may be configured and reconfigured as needed. Vertical corner posts and horizontal beams are also secured together using the single tool and additional hardware. By assembling a plurality of RHUs in this manner, the RHUs can be configured in any complex configuration that will best simulate the indigenous environment desired. A plurality of RHUs can be placed side-to-side, back-to-back, offset, stacked, or staggered to create a multi-level scalable structure. A simple repair kit provides quick easy patching of the composite materials.
BRIEF DESCRIPTION OF THE DRAWINGS
The novel features of this invention, as well as the invention itself, both as to its structure and its operation, will be best understood from the accompanying drawings, taken in conjunction with the accompanying description, in which similar reference characters refer to similar parts, and in which:
FIG. 1 is a front view of a preferred embodiment of a multi-story relocatable habitat unit, “sceniced” to resemble a fortress, showing the use of compound walls, and other features; and
FIG. 2 is an alternative embodiment of a single story construction of the present invention showing another manner in which the relocatable habitat unit can be “sceniced” with additional props to resemble real world tactical environments.
FIG. 3 is a perspective view of an adjustable foot module as it is mounted to the underside of a floor panel;
FIG. 4 is a bottom perspective view of the underside of the corner of a floor panel, showing the set screw that secured the adjustable foot module in place;
FIG. 5 is a perspective view of the bottom of a single floor panel, showing the frame, floor board, four adjustable foot modules, and the lock connectors on the visible sides;
FIG. 6 is a perspective view of the top of a corner of a floor panel, showing a lock connector and the tool used to adjust the height of the adjustable foot module;
FIG. 7 is a perspective view of two floor boards after being leveled using the adjustable foot modules and connected together with each floor panel's respective lock connectors;
FIG. 8 is a perspective is a perspective view of a wall panel as it is attached to the edge of a floor panel, showing the access port for actuating the lock connector on the bottom edge of the wall panel, and the ledges that maintain the wall panel's position on the floor panel allowing the user to connect the wall panel to the floor panel with the lock connectors;
FIG. 9 is a perspective view of a wall panel as attached to a floor panel using the lock connectors, showing the ledges on the bottom edge of the wall panel holding the wall panel in place, and the tool as it would be inserted to actuate the lock connectors;
FIG. 10 is a perspective view of three floor panels connected forming a floor of a relocatable habitat unit, with two wall panels connected to the floor panels and to a corner post;
FIG. 11 is a perspective view of the outside of corner of FIG. 8 , showing the interaction of the corner post as it connects to the two wall panels forming a corner of the relocatable habitat unit;
FIG. 12 is a perspective is a top perspective view of the bottom floor of a relocatable habitat unit prior to installation of the second story, showing eight wall panels installed forming the walls of the relocatable habitat unit, with two doors, and two windows;
FIG. 13 is a view of two corner posts as they interact with a ceiling beam, showing the flanges formed to the corner posts that connect to the ceiling beams, and the ledges formed into the ceiling beam for support of the second story floor;
FIG. 14 is a top perspective view of a complete first story of a relocatable habitat unit prior to the installation of the second story floor, showing four ceiling beams installed between the four corner posts for support of the second floor;
FIG. 15 is a perspective view of the interior of the corner post where the flanges and ceiling beams meet, showing a corner bracket installed, with the hardware inserted through the flanges, through the ceiling beams, and into the cage nuts formed onto the interior of the corner bracket;
FIG. 16 is a perspective view of the top of a corner bracket as installed in a relocatable habitat unit, showing the interaction of two ceiling beams, corner post, and the top of the corner bracket that also serves to support the second story floor;
FIG. 17 is a top view of the installation of the second story floor, showing the lock connectors and the interaction of the edges of the floor panel as is lies atop the ceiling beam flanges and the corner brackets, in addition to a four by four support post installed to support the second story;
FIG. 18 is a perspective view of the underside of a second story floor panel where the four-by-four support post is installed;
FIG. 19 is perspective view of the top of a partially constructed relocatable habitat unit showing the installation of a second floor panel for the second story, offset orientation of the second story floor panels, and the location and interaction of the four-by-four support post;
FIG. 20 is a perspective view of the top of the partially constructed relocatable habitat unit showing the installation of the third second story floor panel having a void adapted to accept a staircase;
FIG. 21 is a perspective view of the installation of the hardware for securing the top of the staircase following installation in the relocatable habitat unit;
FIG. 22 is a perspective side view of a completed first story of a relocatable habitat unit showing a look-through view of the interior of the first floor with a staircase installed for access to the second floor;
FIG. 23 is a perspective view of the top of the nearly completed second story of the relocatable habitat unit showing the top access of the staircase and nine of the ten required panels for the top floor;
FIG. 24 is a perspective view of a completed two story relocatable habitat unit showing the roof panels installed on top of the second story;
FIG. 25 is a side view of the installation of the corner post covers that magnetically adhere to the corner post flanges and complete the exterior finish; and
FIG. 26 is a perspective view of the side of a preferred embodiment of the present in invention showing the one of the many ways in which the relocatable habitat unit can be “sceniced” to resemble a real world building, yet still use the basic units of construction discussed herein.
DETAILED DESCRIPTION
Referring initially to FIG. 1 , a preferred embodiment of a multi-story relocatable habitat unit (“RHU”) of the present invention is shown and generally designated 100 . As will be explained more fully below, the entirety of the RHU is constructed using five basic parts and a single tool and can be sceniced to resemble a real world tactical environment. Stage production techniques are utilized to provide a real world environment, increasing the quality of tactical training while remaining flexible with the execution and assembly.
Referring to FIG. 2 , a preferred embodiment of a single level RHU of the present invention is shown a generally designated 101 . RHU 101 is shown “sceniced” as a hut that might be found in a desert or grassland environment used to simulate real world tactical training. In this Figure a door 124 is shown formed into a wall panel 112 , as will be discussed more fully below. As can be seen in this Figure, wall panels 112 (explain more fully below) can be built to resemble buildings other than square structures. The illusion of the RHU 101 having a wider base than top is provided by adding more material to the bottom portion of the panels 112 than at the top.
Referring now to FIG. 3 , the construction of the RHU 100 begins with one or more floor panels 102 , a portion of which is shown in this Figure with a single adjustable foot module 104 attached. Adjustable foot module 104 is utilized to level the floor panel in relatively flat terrain (preferably less than four percent grade). A single tool (not shown), typically a hex tool and a common ratchet can be employed to secure or adjust every attachment in the RHU 100 .
Floor panels are interchangeable with other floor panels and generally sturdy, being formed of a metal frame such as aluminum, steel, other suitable material, with a wooden or composite floor. Each floor panel 102 is designed to withstand tactical training, on the first level or the second level of RHU 100 .
Referring now to FIG. 4 , the underside of the floor panel 102 is shown where adjustable foot module 104 is inserted into a receiver formed in the floor panel 102 and secured by a set screw 106 . The adjustable foot module 104 can be used on any corner of any floor panel 102 in use.
Referring to FIG. 5 , the underside of a floor panel 102 is shown with four adjustable foot modules 104 inserted into a receiver and secured allowing the user to level the floor panel on the terrain. Each of the floor panels is individually leveled with the adjacent floor panels 102 to maintain a flat platform on which to construct the remainder of the RHU 100 .
Referring to FIG. 6 , the tool 107 is inserted and engages with the adjustable foot module 104 to adjust the height and level of the floor panel 102 . Tool 107 is a notionally a common ratchet set with a hex tool, similar to an Allen wrench and will be used throughout construction of the RHU 100 .
Referring to FIG. 7 , multiple floor panels 102 can then be leveled and attached along their adjacent edges through the use of male (M) lock connectors 108 and female (F) lock connectors 110 . Two floor panels 102 have been connected together, forming a larger floor that will form part of the base of RHU 100 . In a preferred embodiment of RHU 100 , any practical number of floor panels 102 can be connected to create a larger floor plan. Tool 107 is used to connect and disconnect lock connectors 108 and 110 , and secure corner posts and ceiling beams to the RHU 100 .
Referring to FIG. 8 , a wall panel 112 is shown as it would be attached to the edge of a floor panel 102 . The wall panel has ledges 114 that aid in supporting the weight of the wall panels 112 , as the user is securing the M lock 108 on the base of the wall panel 112 to an F lock 110 (not visible from this angle) on the edge of the floor panel 102 . Each of the wall panels 112 has at least one M lock 108 or at least one F lock 110 along the interior face of the bottom edge, where the wall panel 112 comes in contact with floor panel 102 . An access port 115 provides the user with access to fit the tool 107 and actuate the M lock 108 , as depicted by FIG. 9 .
FIG. 9 shows a common ratchet as tool 107 actuating the M lock 108 . Shown are ledges 114 formed into the frame of wall panel 112 that help support the weight of the wall panel 112 during construction. The ledges 114 are not intended to be critical load bearing members once the frame (shown in FIG. 10 ) of the RHU 100 is complete.
Referring to FIG. 10 , two wall panels 112 are shown connected to the floor panels 102 through the use of the M locks 108 and F locks 110 (shown in FIG. 9 ). As the wall panels 112 are secured in place, a corner post 116 is connected to the first wall panel 112 through the use of the M locks 108 and F locks 110 . The corner post 116 is an elongated, metal member with a roughly square cross section. At least two of the adjacent sides that meet wall panels 112 at a given corner have M locks 108 and F locks 110 disposed about the length of the corner post 116 . In an embodiment, a corner post 116 may be formed with appropriate lock connectors 108 and 110 as needed on more than two adjacent surfaces along the corner post's 112 length to accommodate additional designs. Such an embodiment might require a T-shaped intersection where three walls come together, or even four walls, as required.
Referring to FIG. 11 , an opposing view from that of FIG. 10 is shown. Corner post 116 is connected along its length to two wall panels 112 with the use of the M locks 108 and F locks 110 disposed one the edges. This Figure also shows the two flanges 118 orthogonally disposed on adjacent sides of corner post 116 at approximately the height of the wall panels 112 . Flanges 118 are formed with holes 120 to accept hardware 122 that will ultimately secure ceiling beams (discussed below).
Referring to FIG. 12 , ten wall panels 112 are erected around the edges of the three floor panels 102 that form the floor of RHU 100 . Four corner posts 116 are utilized to support the four corners of the first floor of the RHU 100 . As shown, the wall panels 112 can be formed with one of several amenities common in a typical building. Amenities such as a door 124 or a window 126 can be formed into the wall panels 112 as needed. Additionally, the wall panels are interchangeable, being identically built and reconfigurable once the RHU 100 is complete.
In a preferred embodiment, wall panels 112 are formed of a frame composed of pultruded fiberglass reinforced plastic beams, bonded with wood, composite, or expanded polystyrene foam panels that are laser cut and sceniced to replicate the look and texture of various building materials like brick, adobe, mud, wood, bamboo, straw, thatch, among other materials.
Because tactical military training often requires live ordnance, panels may become damaged. The ability to repair or quickly reconfigure a wall panel 112 from a solid wall to a door 124 or window 126 panel is of great utility saving considerable time and money.
Referring now to FIG. 13 , to construct the ceiling attachment assembly, a ceiling beam 128 is secured between flanges 118 in order to both provide structural support to the wall panels 112 , but also to support the second floor of RHU 100 . Tabs 130 are also formed to the interior of beam 128 supplying additional support to the floor panels 102 (shown in FIGS. 3-12 ) that will be employed as the ceiling, or floor of the second story.
Referring now to FIG. 14 , a top perspective view of the first story of the RHU 100 after the remaining ceiling beams 128 are installed creating the ceiling attachment assembly to which the ceiling or next story will be secured is shown.
Referring to FIG. 15 an interior view of a corner bracket 132 is shown installed in the corner where two ceiling beams 128 meet. The corner bracket 132 is formed with at least two orthogonal faces that meet flanges 118 (shown in FIGS. 11-13 ), and holes 134 sized to receive hardware 136 (shown in FIG. 16 ). Hardware is notionally a bolt, capable of being driven by tool 107 , maintaining the simplicity of construction. Additionally, holes 134 in corner bracket 132 can either be internally threaded or alternatively be equipped with cage nuts connected or otherwise formed to the interior of the corner bracket 132 . In an embodiment, just as tabs 130 assist in supporting the floor panels 112 of the second story (or ceiling of the first story), the tops of corner bracket 132 are formed to assist in the support of the same.
Referring to FIG. 16 , a perspective view of the top of a corner bracket 132 is shown as installed between two ceiling beams 128 . Hardware 136 is more clearly shown here as it is inserted to secure the components together.
Referring now to FIG. 17 , the beginning of installation of the second story floor of the RHU 100 is shown, with the addition of a first floor panel 102 . Floor panels on a second story of an RHU 100 do not physically attach to the ceiling beams 128 , but rather rest on the tabs 130 and the corner brackets 132 (shown in FIGS. 15-16 ). The top surface of the tabs 130 and the corner brackets 132 lies below the top of ceiling beams 128 creating a ridge 138 that helps maintain the position of floor panels 102 in use as a second story floor of RHU 100 . In order to maintain integrity of the floor panels 102 , each of the panels 102 in use is connected to the adjacent floor panel 102 with the use of lock connectors 108 and 110 .
This Figure also shows the addition of support post 140 as it is installed to provide additional support to the floor panels 102 as they are installed on the second floor and will support the intersection of the three floor panels 102 in use in this embodiment of RHU 100 .
Support post 140 is provided to create a more secure upper floor. As the surface area of a second story of a multi-level RHU 100 increases, the amount of support to maintain a level second floor also increases. Support post 140 is notionally a four-by-four beam made from any of a number of materials from a composite to metal or wooden members. While weight is a concern, the more important aspect is safety and security of RHU 100 .
FIG. 18 is a perspective view of the interaction of the support post 140 with the bottom of the floor panel 102 . The support post 140 has a registration pin (not shown) in the bottom, that fits into the registration hole (not shown) in the floor panel 102 . The registration hole indicates a strong point in the floor, generally positioned over an intersection of floor panels 102 where the increased support of the adjustable foot module 104 (shown in FIGS. 3-7 ) is located. Thus, support post 140 transfers the load from the intersection of second story floor panels 102 , to the ground through the foot module 104 , decreasing the sheer stresses applied to the floor panels 102 that comprise the second floor of RHU 100 .
Notches 142 formed in the top of the support post 140 are sized to accept the rails 143 formed in the bottom of the second story floor panel. The remaining floor panels 102 are intended to be oriented 90° from the first panel, as shown in FIGS. 19 and 20 . This scheme of manipulating the orientation of the second story floor panels 102 more evenly distributes the loads applied to the second story and ensures a more structurally sound RHU 100 . In an embodiment, it is desirable to support each second story floor panel 102 about all four corners.
Referring to FIG. 19 a second floor panel 102 is installed on the second story floor of RHU 100 , supported on each corner and connected to the adjacent floor panel 102 with lock connectors 108 and 110 .
In FIG. 20 , the third and final second floor panel 102 installed on the second story floor of RHU 100 is shown, this time modified as a stairwell panel 144 , providing a means for installation of a staircase 146 (shown in FIG. 22 ) and access to the second story of the RHU 100 .
FIG. 21 shows the close up of the installation of a staircase 146 , and hardware 148 as would be used to secure the staircase 146 to the stairwell panel 144 .
Referring to FIG. 22 , a side perspective of an almost complete RHU 100 is shown with a look-through to the staircase 146 and the completed first floor.
Referring to FIG. 23 , construction of the walls, using additional wall panels 112 continues as the second story is shown nearly enclosed with nine out of ten wall panels 112 installed. As before, the corner posts secure to adjacent wall panels 112 using lock connectors 108 and 110 , in the same manner in which the lock connectors 108 and 110 are used to secure adjacent wall panels 112 together.
Referring to FIG. 24 , flat roof panels 150 are installed in the same manner in which the floor panels 102 were installed to create the floor of the second story. All flat roof panels 150 are identical and are substantially similar to floor panels 102 . Like floor panels 102 , flat roof panels 150 have male lock connectors 108 on two sides and female lock connectors 110 on two sides. With the wall panels 112 locked into the floor, the lock connectors 108 and 110 in the wall panels 112 will be the correct gender to mate with the roof panels 150 . Note the position of the wall locks and rotate the roof panel to mate with them. The tool 107 (shown in FIGS. 6 and 9 ) is again used to actuate the individual male lock connectors 108 to lock the panels 112 and 150 into place.
The last step in the process of construction of RHU 100 is the addition of the foam corner pieces 152 as shown in FIG. 25 . Foam corner pieces are formed with a magnetic backing that adheres to the exterior of flanges 118 (shown in FIGS. 11-13 ) on corner posts 116 (shown in FIGS. 10-23 ). Alternatively, the foam corner pieces 152 may be attached by utilizing snap locks, hook and loop fasteners, or any other similar fastening methods known in the art.
Referring to FIG. 26 , an alternative preferred embodiment of RHU of the present invention is shown and generally designated 200 . RHU 200 is a round construction, resulting from the ability to vary the shape of the roof panels 150 and the floor panels 102 . In an embodiment, the wall panels 112 need not be symmetrical or uniformly thick throughout their construction adding an illusion that the building is not perfectly square as in RHU 101 of FIG. 2 . While the shape and cut of the panels that comprise the round RHU 200 are not exactly the same size or shape as the floor panels 102 , wall panels 112 , and roof panels 150 , the same concepts and mechanisms are at work. Assembly and disassembly of RHU 200 is as fast and easy and uses the same tool 107 as above.
While the particular Relocatable Habitat Unit 100 of the present invention as herein shown and disclosed in detail is fully capable of obtaining the objects and providing the advantages herein before stated, it is to be understood that it is merely illustrative of the presently preferred embodiments of the invention. No limitations are intended to the details of construction or design herein shown other than as described in the appended claims. | A field-deployable construction set for the assembly of a Relocatable Habitat Unit (RHU), used for simulating real world environments without costly construction expenses. The various panels, supports, and accessories used to construct an RHU provide the user with innumerable options for floor plans and building design, further providing significant options for reconfiguration of floor, ceiling, and wall panels without having to disassemble the structure. The exterior composition of the expanded polymer foam is customizable to provide a realistic environment for high quality training in a versatile system that is deployable by truck or aircraft and can be assembled with only a single tool. | 4 |
This is a divisional of U.S. application Ser. No. 08/258,549, filed Jun. 10, 1994, which is a continuation of U.S. application Ser. No. 07/340,172, filed Feb. 21, 1989, now abandoned, which was the National Stage of International Application No. PCT/EP88/00551, filed Jun. 22, 1988.
FIELD OF THE INVENTION
The invention relates to Hepatitis B surface antigen ("HBs antigen" or "HBsAG") particles which are composed of polypeptides prepared by recombinant DNA processes, DNA sequences coding for these polypeptides and cell lines for the expression of the same. The present invention relates especially to new particles having increased immunogenicity.
BACKGROUND OF THE INVENTION
Expression in Host Cells
Advances in vaccine production techniques have made it possible to synthesize polypeptides corresponding to the HBs antigen is bacteria, yeast and mammalian cells. Transcription of eukaryotic genes in bacteria and yeast, however, adversely affects the efficaciousness of these polypeptides as antigens due to several drawbacks concerning the glycosilation and secretion of the polypeptides and composition of the particle formed therefrom.
For example, in the case of the Hepatitis B virus, the polypeptide antigens produced in vivo are heavily glycosilated (Gerlich, 1984: J. Virol.: 52 (2), 396). In prokaryotes, glycosilation is not an essential process so that polypeptides produced by genetically engineered bacteria are either not glycolsilated or are incompletely glycosilated. In either case, polypeptides corresponding to HBsAg, when expressed in bacteria, do not raise antibodies which will see HBsAg sufficiently well for an effective vaccine. Although yeast as a eukaryotic host is capable of more complete glycosilation, polypeptides corresponding to HbsAg expressed in yeast share the same deficiency as in the case of bacterial expression. (Murray et al., 1979: Nature, 282, 575; Valenzuela et al., 1982: Nature, 298, 347; Miyanohara et al., 1983: PNAS, 80, 1).
As a further example, in bacteria the eukaryotic structural gene of the HBsAg is in most cases not efficiently transcribed. Furthermore the structure and function of the eukaryotic HBsAg gene product may be dependent on the additional post-translational processes of the linkage of disulfide bonds which can not be accomplished by the bacterial host.
Still further, the expressed polypeptide is rarely secreted from the bacterial host cells. They must be lysed to harvest the expressed polypeptide. During the purification process bacterial wall components may contaminate the polypeptide and cause serious allergic reactions or lead to anaphylactic shock in patients.
Finally, eukaryotic promoters usually do not work in bacteria and must be substituted by a bacterial promoter which can result in modification of the polypeptide expressed. (Offensperger et al., 1985: PNAS, 82, 7540; Valenzuela et al., 1980: ICN-UCLA Symp, Mol. Cell. Biol., 18 57).
Formation and Secretion of Particles
The natural forms of Hepatitis B virus ("HBV") and HBV protein occur in three distinct morphologies:
the HBV-virion (Dane particle), which is thought to be the infectious material,
the filaments, and
the 20 or 22 nm particles (hereinafter "20 nm particle") which consist only of a protein envelope.
The most interesting form for an efficient vaccine is the 20 nm particle because 1) the coding sequences are entirely known, 2) it is completely uninfectious, and 3) it causes some useful immunogenicity in a human organism.
The three known components of HBV particles differ in their relative amounts of the protein composition. There are three monomers called the major protein with 226 amino acids, the middle protein with 281 amino acids, and the large protein with 389 or 400 amino acids, depending on the subtype ayw and adw, respectively. The large protein is encoded by the complete sequence of the pre-S 1 -, pre-S 2 - and S-regions, whereas the middle protein is derived from only the pre-S 2 - and S-regions, and finally the major protein from only the S-region (Tiollais et al., 1985: Nature, 317, 489; Dubois et al., 1980: PNAS, 77, 4549; McAlzer et al., 1984: Nature, 307, 178).
The infectious virion of HBV (Dane particles) contains 40-80 times more of the high molecular monomers--the pre-S 1 and pre-S 2 peptides--compared to the 20 nm particle. It is now known that these pre-S polypeptides may be associated with some biological and clinical implications. The polyalbumin receptor on the pre-S polypeptides can bind polymerized albumins from humans and chimpanzees, which are susceptible to HBV (Thung et al., 1983: Liver, 3, 290; Machida et al., 1984: Gastroenterology, 86, 910). This narrow host range and the known receptor for poly human serum albumin on human hepatocytes explain the hepatotropism of HBV: Dane particles are able to contact hepatocytes via poly human serum albumin taken up by hepatocytes from circulation. Based on this evidence the pre-S peptides should be helpful for an efficient vaccine against HBV because its antibody could be expected to block the significant site on Dane particles that are required for entering hepatocytes (Tiollais et al., 1985: Nature, 317, 489; Millich et al., 1985: Science, 228, 1195).
Literature data would also suggest a better protection against the infectious Dane-particle where the pre-S 1 epitope is present in much higher ratio than on the envelope particles.
The vaccine obtained from natural sources (e.g., donor blood), which causes a limited immunogenic protection, contains (almost) none of the pre-S proteins; this is due to two different reasons. First, the purification process is focused on the noninfectious 20 nm particles. These contain at most 1% pre-S 1 peptide compared to 15-20% in the Dane particle (Gerlich, 1984: J. Vir., 52 (2), 396; Tiollais et al., 1985: Nature, 317, 489; Gerlich, 1982: Virology, 123, 436). Second, the 20 nm particles are isolated from sera of anti-HBE positive carriers (Hevac B, HepaVac B) or are digested by proteases during the purification process. This proteolytic digestion has been shown to cut the pre-S-polypeptides leaving only the S monomers. As a result these vaccines contain none or very little pre-S polypeptides.
Therefore there is a demand for a vaccine in the form of HBs antigen particles which possess a high immunogenicity due to the composition of the particle, which undergo glycosilation in the cell and which are secreted continuously from the particle-producing cell.
Reference and Patents
EP-A-72 318 describes the expression of HBsAg in yeast cells, which have been transformed by a vector comprising a yeast replicon, a yeast promoter and a DNA sequence coding for the S peptide.
Laub et al., J. Virol., Vol. 48, No. 1, pp. 271-280, 1983, disclose the construction of a vector starting from simian virus 40 into which the HBsAg including the 163 codon precursor sequence was incorporated. Laub et al. report that CV-1 cells transformed with said vector yield a better expression when the vector contains only the coding sequence for the S protein as compared to the above vector which comprises additionally also the 163 codon precursor sequence.
Also Takeda Chemical Ind., Japanese Patent Application No. J5-8194-897-A describes the expression of the entire pre-S and S peptides. Reference is also made to the expression of the adw subtype.
Feitilson et al., Virology, Vol. 130, pp. 75-90, 1983, have described the partial expression of polypeptides within the pre-S coding sequence, including species with 24000, 28000, 32000, 43000 and 50000 dalton.
Further, DE-OS 34 39 400 describes the expression of an immunogenic polypeptide sequence of Hepatitis B virus.
Said sequence represents a partial sequence of the pre-S 1 polypeptide, comprises 108 or 119 codons and starts with the first starting codon of HBsAg, and terminates 281 codons in front of the stop codon.
EP-A-154 902 discloses a Hepatitis B vaccine which contains a peptide with an amino acid chain of at least six consecutive amino acids within the pre-S chain coding region of the envelope of Hepatitis B virus. This vaccine is free of an amino acid sequence corresponding to the naturally occurring envelope proteins of Hepatitis B virus.
Also Kent et al. have described in Pept. Chem., Vol 22, pp. 16770, 1984, that a chemically synthesized peptide comprising the N-terminal 26 amino acids of the pre-S 2 region can serve as an antigen and may therefore be suitable as a synthetic vaccine.
OBJECTS OF THE INVENTION
None of the above discussed references consider the possibility that, by altering the composition of the monomers making up the 20 nm particles and approaching thereby the natural composition of the Dane particles, the antigenicity of the particles can be improved.
As discussed mentioned above, the immunogenicity of the peptide monomers of the virus envelope protein is very poor compared to assembled protein particles. The object of this invention is the development of protein particles which contain an amount of the pre-S polypeptide epitopes comparable to the natural composition of the surface structure of the infectious Dane particle.
It is a further object to utilize additional pre-S peptides containing important protective epitopes in the development of a better immune response, a longer protection and lower non-responder rate as compared to all the other products either already marketed or under development.
It is a further object to express HBsAg in mammalian cells. This requires overcoming known difficulties where expression of the desired peptide in a mammalian cell can result in:
different regulatory mechanism for the three translational/(transcriptional) products
promoter-promoter inhibition
different strength of the start codons
not all peptides expressed.
SUMMARY OF THE INVENTION
The term "HBV S peptide" as used herein refers to the peptide encoded by the entire S region of the HBV genome. The term "HBV pre-S 2 peptide" as used herein refers to the peptide encoded by the entire pre-S 2 and S regions of the HBV genome. The term "HBV pre-S 1 peptide" as used herein refers to the polypeptide encoded by the entire pre-S 1 , pre-S 2 and S regions of the HBV genome. The term "epitope" as used herein refers to a sequence of at least six consecutive amino acids encoded by the designated genome region (e.g., a "HBV pre-S 2 epitope" refers to a sequence of at least six amino acids encoded by the pre-S 2 region of the HBV genome). As used herein "antigenicity" means the ability to provoke an immune response (e.g., acting as a vaccine or an antigen), the ability to cause the production of antibodies (e.g. acting as an antigen) and/or the ability to interact with a cell surface receptor so as to enhance an immune response or production of antibodies (e.g., reacting with a T-cell surface receptor to enhance immune response).
The term "HBV" means any subtype of the virus, particularly adw, ayw, adr and ayr, described in the literature (P. Valenzuela, Nature Vol. 280, p. 815 (1979), Gerlich, EP-A-85 111 361, Neurath, EP-A-85 102 250). Examples of peptide sequences thereof, from which the epitopes of this invention can be derived are shown in FIGS. XVI to XX.
In accordance with the present invention, recombinant DNA molecules are disclosed which comprise a first DNA sequence and a second DNA sequence. The first DNA sequence encodes for expression of an amino acid sequence a portion of which displays the antigenicity of an epitope selected from the group consisting of an HBV pre-S 1 epitope and an HBV pre-S 2 epitope. The second DNA sequence encodes for expression of a peptide which upon secretion will form particles which are at least 10 nm in diameter. These particles are believed to be the smallest particles which will effectively form a good vaccine. Preferably the peptide which upon secretion will form particles which are at least 10 nm in diameter is either HBV S peptide, HBV core antigen, polio surface antigen, Hepatitis A surface antigen, Hepatitis A core antigen, HIV surface antigen and HIV core antigen. A substantial portion or all of the HBV S peptide is especially preferred as the peptide encoded by the second DNA sequence. In the recombinant DNA molecules encoding for the first and second DNA sequences must be (1) in the same reading frame, (2) encode for respective discrete regions of a single peptide, and (3) be operatively linked to an expression control sequence. Finally, these recombinant DNA molecules are free of DNA sequences encoding for the expression of the entire HBV pre-S 1 peptide or HBV pre-S 2 peptide.
Specific recombinant DNA molecules of the present invention are also disclosed wherein the first DNA sequence comprises a nucleotide sequence corresponding to the nucleotide sequence of (1) the HBV pre-S 1 and pre-S 2 regions from which the pre-S 2 start codon ATG has been deleted, (2) the HBV pre-S 1 and pre-S 2 regions and wherein the sequences flanking the pre-S 1 ATG have been changed from the natural sequence, (3) the HBV pre-S 1 and pre-S 2 regions and wherein the sequences flanking the pre-S 2 ATG have been changed from the natural sequence, (4) the HBV pre-S 1 and pre-S 2 regions and wherein the 5' terminus of the pre-S 1 region has been deleted, (5) the HBV pre-S 1 and pre-S 2 regions and wherein the 5' terminus of the pre-S 2 region has been deleted, (6) the HBV pre-S 1 region and wherein the 3' terminus of the pre-S 1 region has been deleted, (7) the HBV pre-S 2 region and wherein the 3' terminus of the pre-S 2 region has been deleted, (8) the HBV pre-S 1 and pre-S 2 regions from which the pre-S 2 ATG has been deleted and the second DNA sequence comprises a sequence corresponding to the nucleotide sequence of the HBV S region from which the S ATG has been deleted, and/or (a) an oligonucleotide described in Table I.
Host cells transfected with the recombinant DNA molecules of the present invention are also disclosed. As used herein, "transfected" or "transfection" refer to the addition of exogenous DNA to a host cell whether by transfection, transformation or other means. Host cells include any unicellular organism capable of transcribing and translating recombinant DNA molecules including without limitation mammalian cells, bacteria and yeast. Host cells of the present invention may also be cotransfected with a second recombinant DNA molecule comprising a DNA sequence encoding for expression of an amino acid sequence corresponding to a substantial portion or all of the amino acid sequence of the HBV S peptide.
Peptides are also disclosed comprising a first discrete region and a second discrete region. The first region displays the antigenicity of an epitope of an HBV pre-S 1 epitope or an HBV pre-S 2 epitope. The second region correspond to a substantial portion of a peptide which upon secretion will form particles which are at least 10 nm in diameter. Preferably the peptide which upon secretion will form particles which are at least 10 nm in diameter in either HBV S peptide, HBV core antigen, polio surface antigen, Hepatitis A surface antigen, Hepatitis A core antigen, HIV surface antigen and HIV core antigen. A substantial portion or all of the HBV S peptide is especially preferred. Preferably, the first region is located closer to the N-terminus of the peptide than the second region.
Immunogenic particles are also disclosed which comprise a plurality of first peptide monomers. Each of said first peptide monomers comprises a first discrete region and a second discrete region which can be the same as the first and second discrete regions of the peptides described above. Immunogenic particles are also disclosed which further comprise a plurality of second peptide monomers and wherein the first and second peptide monomers are bound together by interactive forces between the monomers. Each of said second peptide monomers comprising an amino acid sequence corresponding to a substantial portion of or all of the amino acid sequence of the HBV S peptide.
Immunogenic particles are also disclosed which contain substantially more than one percent, preferably more than five percent, of the pre-S 1 epitope. As used herein, a particle "contains one percent" of a designated epitope if peptide monomers having the designated epitope constitute one percent of all protein in the particle. Immunogenic particles which contain substantially more than ten percent, preferably more than fifteen percent, of the pre-S 2 epitope are also disclosed.
Pharmaceutical preparations and preparations useful for production of antibodies comprising the above-described immunogenic particles in sufficient concentration to elicit an immune response upon administration of said preparation and a suitable carrier are also disclosed. Suitable carriers are known to those skilled in the art and may include simple buffer solutions.
Other preparations useful for production of antibodies are disclosed comprising the above-described immunogenic particles in sufficient concentration to elicit an immune response upon administration of said preparation and a suitable carrier. Suitable carriers are known to those skilled in the art and may include simple buffer solutions.
A process for producing a transfected host cell is disclosed which comprises providing host cells which have been made competent for uptake of DNA, exposing the host cells to a first preparation of DNA comprising one of the above-described recombinant DNA molecules, allowing under suitable conditions the host cells to take up DNA from the first preparation of DNA, and selecting for host cells which have taken up exogenous DNA. The process may further comprise exposing the host cells to a second preparation of DNA comprising a DNA molecule encoding for a peptide including the amino acid sequence of the HBV S peptide and allowing under suitable conditions the host cells to take up DNA from the second preparation of DNA. The exposure and uptake of the second preparation of DNA can be done before or after exposure to and uptake of the first DNA preparation. Alternatively, the first DNA preparation can also include a DNA molecule encoding for a peptide including the amino acid sequence of the HBV S peptide.
A method for producing a peptide is also disclosed which comprises preparing an above-described recombinant DNA molecule, transfecting a host cell with the recombinant DNA molecule, culturing the host cell under conditions allowing expression and secretion of protein by the host cell, and collecting the peptide produced as a result of expression of DNA sequences within the recombinant DNA molecule. The peptide produced by such method can contain less than the entire amino acid encoded by the coding region of the recombinant DNA molecule. This may result from transcription and/or translation of only a portion of the coding region of the recombinant molecule or by deletions made in the peptide after translation.
A method of producing immunogenic particles is disclosed comprising preparing an above-described recombinant DNA molecule, transfecting a host cell with the recombinant DNA molecule, culturing the host cell under conditions allowing expression and secretion of protein by the host cell, and allowing under suitable conditions the aggregation of peptide monomers produced as a result of expression of exogenous DNA sequences within the host cell. A method of producing immunogenic particles is also disclosed which further comprises transfecting (cotransfection) the host cell with a DNA molecule encoding for a peptide including the amino acid sequence of the HBV S peptide. The cotransfection can occur before, after or simultaneous with the transfection of the above-described recombinant DNA molecule. Presence of peptides encoded by the cotransfected DNA molecule are necessary to obtain more than trace amounts of particles secreted from the host cell.
Methods of manufacturing a pharmaceutical preparation and a preparation useful for production of antibodies are disclosed comprising preparing an above-described recombinant DNA molecule, transfecting a host cell with the recombinant DNA molecule, culturing the host cell under conditions allowing expression and secretion of protein by the host cell, allowing under suitable conditions the aggregation of peptides produced as a result of expression of DNA sequences within the host cell to form immunogenic particles, and combining the immunogenic particles with a suitable carrier such that the immunogenic particles are present in sufficient concentration to cause production of antibodies upon administration of a preparation to an individual. Host cells used in these methods can also be cotransfected as previously described.
BRIEF DESCRIPTION OF THE FIGURES
FIG. 1 shows gene constructs a polypeptide including the HBV pre-S1 region and a portion of the S region. The gene constructs also include the U2 promotor (FIG. 1A) the MT promotor (FIG. 1B) or the H2K promotor (FIG. 1C). The open boxes at the top of each figure signify inserts derived from the HBV genome, and the extent of deletions are indicated by the shaded segments thereof.
FIG. 2 shows gene constructs encoding a polypeptide including a portion of the HBV pre-S2 region and a portion of the S region. The gene constructs also include the U2 promotor (FIG. 2A) the MT promotor (FIG. 2B) or the H2K promotor (FIG. 2C). The open boxes at the top of each figure signify inserts derived from the HBV genome, and the extent of deletions are indicated by the shaded segments thereof.
FIG. 3 shows gene constructs encoding a polypeptide including a portion of the HBV pre-S1 region and a portion of the pre-S2 S region, and a portion of the S region. The gene constructs also include the U2 promotor (FIG. 3A), the MT promotor (FIG. 3B) or the H2K promotor (FIG. 3C). The open boxes at the top of each figure signify inserts derived from the HBV genome, and the extent of deletions are indicated by the shaded segments thereof.
FIG. 4 shows gene constructs encoding a polypeptide including at least a portion of the HBV pre-S1 region inserted within the S region at the XbaI site within S with a total deletion of the pre-S2 region. The gene constructs also include the U2 promotor (FIG. 4A), the MT promotor (FIG. 4B) or the H2K promotor (FIG. 4C). The open boxes at the top of each figure signify inserts derived from the HBV genome, and the extent of deletions are indicated by the shaded segments thereof.
FIG. 5 shows gene constructs encoding a polypeptide including at least a portion of the HBV pre-S2 region inserted within the S region at the XbaI site within S with a total deletion of the pre-S1 region. The gene constructs also include the U2 promotor (FIG. 5A), the MT promotor (FIG. 5B) or the H2K promotor (FIG. 5C). The open boxes at the top of each figure signify inserts derived from the HBV genome, and the extent of deletions are indicated by the shaded segments thereof.
FIG. 6 shows gene constructs encoding a polypeptide including a portion of the HBV pre-S1 region and the S region with deletion of the S ATG. The gene constructs also include the U2 promotor (FIG. 6A) the MT promotor (FIG. 6B) or the H2K promotor (FIG. 6C). The open boxes at the top of each figure signify inserts derived from the HBV genome, and the extent of deletions are indicated by the shaded segments thereof.
FIG. 7 shows gene constructs encoding a polypeptide including a portion of the HBV pre-S2 region and the S region with deletion of the S ATG. The gene constructs also include the U2 promotor (FIG. 7A) the MT promotor (FIG. 7B) or the H2K promotor (FIG. 7C). The open boxes at the top of each figure signify inserts derived from the HBV genome, and the extent of deletions are indicated by the shaded segments thereof.
FIG. 8 shows gene constructs encoding a polypeptide including a portion of the HBV pre-S1 region, a portion of the pre-S2 region, and the S region with deletion of the S ATG. The gene constructs also include the U2 promotor (FIG. 8A), the MT promotor (FIG. 8B) or the H2K promotor (FIG. 8C). The open boxes at the top of each figure signify inserts derived from the HBV genome, and the extent of deletions are indicated by the shaded segments thereof.
FIG. 9 shows the nucleotide sequence of the pre-S1/pre S2/S region of the HBV genome. Restriction sites (Bg1II, MstII, and XbaI) and start codons for pre-S1 protein ("S1"), pre-S2 protein ("S2"), and S protein ("S") are underlined.
FIG. 10 shows gene constructs encoding a polypeptide including at least a portion of the HBV pre-S2 region and the S region with deletion of the S ATG. The gene constructs also include the U2 promotor (FIG. 10A), the MT promotor (FIG. 10B) or the H2K promotor (FIG. 10C). The open boxes at the top of each figure signify inserts derived from the HBV genome, and the extent of deletions are indicated by the shaded segments thereof.
FIG. 11 shows a CsC1 sedimentation profile of particles comprising polypeptides produced by the gene constructs of FIGS. 1 and 6.
FIG. 12 shows a CsC1 sedimentation profile of particles comprising polypeptides produced by the gene constructs of FIGS. 2 and 7.
FIG. 13 shows a gene constructs, pRSV-HBV, which contains a 2.3 kb Bg 1II-Bg1II fragment containing the HBV pre-S1, pre-S2 and S coding regions.
FIG. 14 shows a CsC1 sedimentation profile of particles comprising polypeptides comprising pre-S1, pre-S2 and S epitopes.
FIG. 15 shows the nucleotide sequence that encodes the HBV pre-S2 region and a portion of the S region, found in the gene constrtuct of FIG. 10B.
FIG. 16 shows the amino acid sequence of pre-S polypeptide from HBV subtypes ayw, adyw, adw2, adw and adr, from which pre-S1 epitopes of the invention can be derived.
FIG. 17 shows the nucleotide and amino acid sequences of the pre-S1 region from HBV subtype adr.
FIG. 18 shows the nucleotide and amino acid sequences of the pre-S1 region from HBV subtype ayw.
FIG. 19 shows the nucleotide and amino acid sequences of the pre-S1 region from HBV subtype adw2.
FIG. 20 shows the nucleotide and amino acid sequences of the pre-S1 region from HBV subtype adw.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Preferred DNA constructs of the present invention are characterized by the presence of a selection marker selected from the group consisting of dhfr (dihydrofolate reductase), MT-neo (a neomycin resistance sequence coupled to a methallothionein and MT-ecogpt (a resistance sequence coupled to a methallothionein promoter). The expression rate may be further enhanced by adding to the constructs a dhfr gene as an amplification gene.
HBV nucleotide sequences used in certain constructs of the present invention can be formed or isolated by any means including isolation and ligation of restriction fragments and synthetic oligonucleotides. Constructs specifically described herein were formed by the ligation of synthetic oligonucleotides to a 5' XbaI-BglII 3' fragment from the S region of the HBV genome shown in FIG. IX (hereinafter the "XbaI-BglII fragment") which is derived from a BglII-BglII HBV fragment including the entire pre-S 1 -pre-S 2 -S regions (the "BglII-BglII Fragment"). The pre-S 1 -pre-S 2 -S region of the HBV genome is shown in FIG. 9. Oligonucleotides used in making such constructs are summarized in Table I.
TABLE I__________________________________________________________________________Oligonucleotide Duplexes for Vector Construction Restriction Sites and Sequence (5'-3'Oligo No. Schematic Structure Function (sticky ends are underlined)__________________________________________________________________________1 MSTII-ATG-S1-XbaI S1 (exchanged TCAGGAAATGGAGAACATATCAGGA flanking TTCCTAGGACCCCTTCTCGTGTTACAG sequence GCGGGGTTTTTCTTGTTGACAAGAATC ATG) CTCACAATACCGCAGAGT13 MstII-ATA-S1-XbaI S1 (exchanged TCAGGAAATAGAGAACATATCAGGA flanking TTCCTAGGACCCCTTCTCGTGTTACAGG sequence CGGGGTTTTTCTTGTTGACAAGAATCCT ATA) CACAATACCGCAGAGT17 BglII-ATG-S2-EcoRI S2 (exchanged GATCTACCTGAACATGGAGTGG flanking sequence ATG)19 MstII-ATG(S)-S2- S2 (20 amino TCAGGCGCTGAACATGGAGAACATCTCC XhoI acids; with S AGTTCAGGAACAGTAAACCCTGTTCTGA ATG) CTACTGCCTCTCCCTTATCGTCAATCTTC23 BglII-ATG(S)-S1- S1 (28 amino GATCTTTAACATGGAGAACAATCCTCTG XbaI acids; with S GGATTCTTTCCCGATCACCAGTTGGATCC ATG) AGCCTTCAGAGCAAACACCGCAAATCC AGATTGGGACTTCAATCCCAGT29 BglII-ATG(S)-S2- S2 (26 amino GATCTTTAACATGGAGAACCAGTGGAAT XbaI acids; with S TCCACAACCTTCCACCAAACTCTGCAAG ATG) ATCCCAGAGTGAGAGGCCTGTATTTCCCT GCTGGTGGCTCCAGT33 XbaI-ATA(S)-StyI S 5' with ATA CTAGACCCTGCGCTGAACATAGAGAACA TCACATCAGGATTCCTAGGACCCCTTCTC GTGTTACAGGCGGGGTTTTTCTTGTTGACA AGAATCCTCACAATACCGCAGAGC35 XbaI-ATA(S)-HpaI- S 5' with ATA CTAGACCCTGTGGTTAACATAGAGAACA StyI TCACATCAGGATTCCTAGGACCCCTTCTC GTGTTACAGGCGGGGTTTTTCTTGTTGACA AGAATCCTCACAATACCGCAGAGC37 BglII-S1-HpaI S1 GATCTTTAACATGGAGAACAATCCTCTG GGATTCTTTCCCGATCACCAGTTGGATCC AGCCTTCAGAGCAAACACCGCAAATCC AGATTGGGACTTCAATGTT39 EcoRI-XbaI-XhoI- S 5' with ATA AATTCTAGACTCGAGTCTGAACATAGAG ATA(S)-StyI AACATCACATCAGGATTCCTAGGACCCC TTCTCGTGTTACAGGCGGGGTTTTTCTTGT TGACAAGAATCCTCACAATACCGCAGA GC43 StyI-S2-XhoI S 3' CTAGGAACAGTAAACCCTGTTCTGACTA CTGCCTCTCCCTTATCGTCAATCTTCTCTA GGATTGGGGAC45 BglII-ATG(S)-S1- S1 (17 amino GATCTTTAACATGGAGAACGATCACCAG poly alanine-XbaI acids; with S TTGGATCCAGCCTCCAGAGCAAACACCG ATG); poly CAGCCGCCGCCGCCGCCGCCGCCGCCGCCG alanine sequence CCGCCGCCGCCGCCAAT49 XbaI-S2-StyI S 3' CTAGACACAGTAAACCCTGTTCTGACTA CTGCCTCTCCCTTATCGTCAATCTCGA GGATTGGGGAC55 BglII-S1-XbaI S1 (28 amino GATCTTTAACATGGAGACCAATCCTCTG acids) GGATTCTTTCCCGATCACCAGTTGGATCC AGCCTTCAGAGCAAACACCGCAAATCC AGATTGGGACTTCAAT__________________________________________________________________________
The oligonucleotides in Table I were combined with the XbaI-BglII fragment to produce constructs with desired features. In certain constructs adapter oligonucleotide sequences (Table II) were used to create proper matching sticky ends on the oligonucleotides and other construct components.
TABLE II__________________________________________________________________________Oligonucleotide Duplexes (Adapter Sequences) Restriction Sites andOligo No. Schematic Structure Sequence (5'-3')__________________________________________________________________________2 ApaI-BglII-HindIII CTTAGATCTTTA CCGGGAATCTAGAAATTCGA4 MstII-XhoI TCAGGAC CCTGAGCT7 EcoRI-HindIII-BglII AATTCAAGCTTA GTTCGAATCTAG9 SalI-BglII-BamHI TCGACAGATATG GTCTAGACCTAC15 EcoRI-BglII AATTCCCCGGGA GGGGCCCTCTAG27 EcoRI-BglII-BamHI- AATTCAGATCTGGATCCGAGCTCA HindIII GTCTAGACCTAGGCTCGAGTTCGA31 BamHI-HindIII GATCCTTA GAATTCGA41 ApaI-BglII-XhoI CAAAAGATCTTTTC CCGGGTTTCTAGAAAAGAGCT47 XbaI-polyalanine-XhoI CTAGAC(2OH GCC)GAC TG(2OH CGG)CTGAGCT53 EcoRI-BglII-XbaI-XhoI AATTCATCCAGATCTAATTCTCTAGATTAC GTAGGTCTAGATTAAGAGATCTAATGAGCT57 XhoI-XbaI TCGAGGAGTCGACCTAGT CCTCAGCTGGATCAGATC61 BglII-EcoRI-BglII GATCTAATTGAATTCAATTA ATTAACTTAAGTTAATCTAG63 EcoRI-SalI-EcoRI AATTATGTCGACTA TACAGCTGATTTAA__________________________________________________________________________
Other adapter sequences may be used to combine desired oligonucleotides from Table I with the XbaI-BglII fragment, other restriction fragments, oligonucelotides and other construct components. The necessary sequences of such other adapter sequences will be readily apparent to those skilled in the art from consideration of tables of restriction sites [e.g., that found at pages 121-128 of Methods of Enzymology, volume 152, "Guide to Molecular Cloning Techniques," ed. Berger and Kimmel (Academic Press 1987) which is incorporated herein in its entirely by reference] and the sequences of the various nucleotides to be combined. Adapter sequences can also be used to introduce additional restriction sites into constructs of the present invention. It should be noted that adapter sequences must be selected or designed so that the proper reading frame is maintained throughout the HBV sequence.
Preferred gene constructs which were used to transfect host cells were prepared by recombinant DNA techniques in accordance with the present invention. Preferred embodiments of constructs with an enhanced expression rate are shown in FIGS. I-VIII and are schematically represented by the following:
pU2-structural gene
pU2-structural gene-dhfr
pU2-structural gene-dhfr-MT-neo
pU2-structural gene-dhfr-MT-egpt
pMT-structural gene-dhfr
pMT-structural gene-dhfr-MT-neo
pMT-structural gene-dhfr-MT-egpt
pH2K-structural gene-dhfr
pH2K-structural gene-MT-neo
pH2K-structural gene-MT-egpt
pH2K-structural gene-dhfr-MT-neo
pH2K-structural gene-dhfr-MT-egpt
Each of the constructs shown in FIGS. I-VIII contain, in addition to a HBV sequence, a neomycin selection marker with the MT promoter, an ampicillin selection marker, a dhfr selection/amplification gene and a promoter for the HBV sequence. The promoter for the HBV sequence is preferably the U2 promoter, the MT promoter of the H2K promoter. Isolation of fragments containing the various promoters, the selection markers and amplifications gene is described below. The HBV sequences in the constructs of FIGS. I-VIII are schematically represented by a rectangular bar in each figure which indicates the oligonucleotides and/or adapter sequences from Tables I and II which were combined with the XbaI-BglII fragment. Shaded areas within the bar indicate generally regions of the entire pre-S 1 -pre-S 2 -S region which are not found in the specific construct. Oligonucleotides from Table I which can be used to construct each type of HBV sequence are indicated in the figures.
FIG. 10 depicts two additional constructs for expression of peptides including sequence from the pre-S2 region under the control of the MT promoter.
Constructs have also been made which include the entire BglII-BglII fragment from the HBV genome under the control of the US promoter. These constructs have produced peptides which include a deletion in the S region as indicated by Western blot analysis.
The above-cited promoters are specially preferable when their use is coupled with a modulation method using the dhfr gene and methotrexate to enhance the expression. This is achieved when in addition to the selection marker the dhfr minigene is also introduced into the plasmid sequence. It is essential that the dhfr gene is located on the same plasmid together with the structural gene to be expressed. An enhancement of the expression rate of the structural gene can then be obtained by adding methotrexate in the micromolar concentration range. Thereby a manyfold enhancement of the expression rate is achieved.
Suitable cells are e.g. VERO cells (monkey kidney cell line), 3T3-cells (murine fibroblast line), C127-cells (murine fibroblast line), L-cells and CHO-cells (Chinese hamster cells, which are either positive or negative in dehydrofolate reductase).
As a stop signal it is preferred to use a stop signal from a eukaryotic cell. Preferably the stop signal of the caseine DNA-sequence is used. As used throughout the following example, "HBV protein" refers generically to any protein produced in accordance with the present invention which corresponds to HBsAg sequences.
EXAMPLE 1
Particle Purification Procedures
1. Fractionated precipitation with polyethylene glycol (PEG)
The supernatant of HBV protein producing cultures was collected and split into portions of 2,400 ml. To each portion 144 g of PEG 6000 (Serva) were added and dissolved by stirring at room temperature for 20 minutes and was stirred for another 6 hours at 4° C. The precipitate was separated by centrifugation in 500 ml bottles in a GS 3 rotor at 9,000 rpm (15,000×g) for 30 minutes at 10° C. The supernatant was collected and 144 g of PEG 6000 were added and dissolved as described above. The solution was stirred at 4 C for 3 hours. The precipitate from this solution was harvested as described above except that centrifugation was continued for 60 minutes.
2. Gel Chromatography
The material obtained after PEG precipitation was redissolved in 20 ml PBS and submitted to gel chromatography on A-5 m (BioRad). Column dimensions were 25×1000 mm and 480 ml bed volume. In a typical fractionation run 1,000 ug of PEG precipitated HBV protein in 10 to 15 ml was loaded and eluted with PBS at a speed of 6 drops/min (18 ml/h) 3 ml fractions were collected. HBV protein eluted with the first peak. Collected fractions were submitted to a CsCl gradient.
3. Sedimentation in CsCl Gradient
About 30 fractions covering the first peak in column chromatography on A-5 m and containing prepurified HBV protein were collected to approximately 100 ml. This solution was adjusted to a density of 1.30 g/cc with CsCl and subsequently transferred to a nitrocellulose tube fitting into a SW 27/28 rotor (Beckman). A gradient was set by underlaying 4 ml of a CsCl solution of 1.35 g/cc and by overlaying 4 ml of 1.25 g/cc followed by 4 ml of 1.20 g/cc density. This gradient had been run at 28,000 rpm for 50 hours at 10 C. Thereafter the gradient was fractionated and purified HBV protein floating in the 1.20 g/cc density layer was collected. The solution was desalted by three cycles of dialysis in bags against water.
EXAMPLE 2
Quantitative Determination of HBV protein
1. with Radioimmunoassay
In the AUSRIA II-125 "sandwich" radioimmunoassay (commercially available from Abbot), beads coated with guinea pig antibody to Hepatitis B Surface Antigen (Anti-HBs) were incubated with serum or plasma or purified protein and appropriate controls. Any HBsAg present was bound to the solid phase antibody. After aspiration of the unbound material and washing of the bead, human 125T-Anti-HBs was allowed to react with the antibody-antigen complex on the bead. The beads were then washed to remove unbound 125 I-Anti-HBs.
______________________________________)-Anti-HBS HBSAg)-Anti-HBs . HBSAg 125I-Anti-HBs)-Anti-HBs . HBSAg . 125-Anti-HBs______________________________________
The radioactivity remaining on the beads was counted in a gamma scintillation counter.
2. with ELISA
In the Enzygnost HBsAg micro "sandwich" assay (commercially available from Behring), wells were coated with anti-HBs. Serum plasma or purified protein and appropriate controls were added to the wells and incubated. After washing, peroxidase-labelled antibodies to HBsAg were reacted with the remaining antigenic determinants. The unbound enzyme-linked antibodies are removed by washing and the enzyme activity on the solid phase is determined. The enzymatically catalyzed reaction of hydrogen peroxide and chromogen was stopped by adding diluted sulfuric acid. The colour intensity was proportional to the HBsAg concentration of the sample and was obtained by photometric comparison of the colour intensity of the unknown samples with the colour intensities of the accompanying negative and positive control sera.
EXAMPLE 3
Preparation of a construct of the present invention containing the methallothionein promoter.
1) Isolation of the MI promoter
The plasmid pBPV-342-12 (commercially available from ATCC) was digested with the endonucleases BglII and BamHI. Three DNA molecules were generated. The fragment of interest contains the methallothionein promoter and a pBR322 sequence comprising 4.5 kb and is easily detectable from the other fragments (2.0 kb and 7.6 kb).
The reaction was performed in a total volume of 200 ul of reaction buffer at a final concentration of 0.5 ug/ul DNA including 100 units of each restriction enzyme. The completion of the digestion was checked after incubation at 37° C. for three hours by agarose gel electrophoresis at a 0.8% agarose gel. The reaction was stopped by adding 4 ul 0.5 M EDTA.
The 4.5 kb fragment was separated from the other fragments by preparative 1.2% agarose gel electrophoresis. The DNA was eluted from the agarose gel on DE-81 Whatman filter paper from which the DNA was removed in a high salt buffer. The DNA was purified by a phenol/chloroform extraction and two ethanol precipitations.
2) Ligation of the 2.3 kb MBV BglII-BglII fragment
A 2.3 kb BglII-BglII fragment containing the HBV pre-S 1 ,pre-S 2 and S coding regions was isolated from HBV-containing DNA. The 2-3 kb fragment was ligated together with the 4.5 kb fragment (obtained as described in C1) containing the methallothionein promoter.
2 ul of the 2.3 kb fragment were mixed with 3 ul of the 4.5 kb fragment and ligated together in a total volume of 10 ul ligation buffer, containing 2 units T 4 -DNA ligase and 2 mM ATP at 14° C. overnight.
The ligation mixture was added to 150 ul competent bacterial cell suspension for DNA up-take. After the DNA up-date the bacterial cells were spread on LB agar plate containing 50 ug/ml ampicillin at volumes of 50 to 300 ul cell suspension per plate. The agar plates were incubated at 37° C. overnight. Single isolated bacterial colonies were screened for the presence of a plasmid containing the desired fragments.
3) Screening for desired plasmid containing bacterial colonies.
Single colonies were picked with a toothpick and transferred to a LB-ampicillin media containing tube (5 ml). The tubes were incubated overnight at 37° C. by shaking rapidly. A mini-plasmid preparation of each grown bacterial suspension was made. The different resulting DNAs were proved by digestion with the restriction endonuclease EcoRI. Two molecules were expected, a 2.2 kb fragment and a 4.6 kb fragment. The digestion was analysed by agarose gel electrophoresis. Plasmid DNA was isolated from the bacterial cells.
4) Conversion of a part of the HBV-gene sequence.
The plasmid resulting from (3) above was digested with the endonuclease BglII and XbaI. Two molecules were expected, one 550 bp fragment and one 6.250 kb fragment which was isolated after agarose gel electrophoresis.
The 6.250 kb fragment was ligated together with oligomecleotide No. 55 from Table I. The ligation mixture was added to 150 ul competent bacterial cell suspension for DNA up-take. Single isolated bacterial colonies were screened for the presence of the desired plasmid. The new plasmid was proved by a digestion with the endonucleases EcoRI and BglII. Two molecules were expected, one 1.9 kb and one 4.450 kb.
5) Insertion of a neomycin selection marker.
The plasmid resulting from (4) above was linearized by digestion with the restriction enzyme EcoRI. The reaction was performed in a total volume of 50 ul and a final concentration of 1 ug/ul plasmid DNA. 50 units of EcoRI were added and the digestion was proved after incubation at 37° C. for three hours by agarose gel electrophoresis. The reaction was stopped by adding 1 ul of 0.5 M EDTA and the DNA was precipitated with a final concentration of 0.3 M sodium acetate and 3-4 volumes of ethanol at -80° C. for 30 minutes. The precipitated DNA was dissolved in 50 ul distilled water.
2 ul of the linearized plasmid were mixed with 3 ul of the DNA fragment containing the methallothionein promoter and the neomycin selection gene [isolated from the plasmid pMT-neo-E (available from ATCC) by digestion with the endonuclease EcoRI ad a 4 kb fragment], and ligated together. Single bacterial colonies were screened for the presence of the desired plasmid.
6) Additional of the dhfr Amplification Gene dhfr
The plasmid pdhfr3.2 (available from ATCC) was digested with the restriction endonuclease HindIII. Two molecules were generated, one of 3,000 bp containing the dhfr gene sequence and one of 3,400 bp. The 3,000 bp fragment was isolated and ligated into the plasmid resulting from (5) above which was previously opened by digestion with HindIII. The resulting plasmid is represented by FIG. 1B.
EXAMPLE 4
1) Isolation of a fragment containing the U2 promoter sequence.
The plasmid pUC-8-42 (available from Exogene) was digested with the restriction endonucleases EcoRI and ApaI. Two DNA molecules were generated. The fragment of interest contains the U2-promoter comprising 340 bp and is easily detectable from the other fragment (3160 bp). The digestion was performed in a total volume of 200 ul of reaction buffer at a final concentration of 0.5 ug/ul DNA including 100 Units of each restriction enzyme. The completion of the digest was checked after incubation at 37° C. for three hours by agarose gel electrophoresis in a 0.7% agarose gel. The reaction was stopped by adding 4 ul 0.5 M EDTA. The 340 bp fragment was separated from the plasmid DNA by preparative 1.2% agarose gel electrophoresis. The DNA was eluted from the agarose gel on DE-81 Whatman filter paper from which the DNA was removed in a high salt buffer. The DNA was purified by a phenol/chloroform extraction and two ethanol precipitations.
2) Insertion of the fragment containing the promoter sequence into a polylinker plasmid.
The plasmid pSP165 (commercially available from Promega Biotec) containing a polylinker sequence (containing the following restriction sites: EcoRI, SacI, SmaI, AvaI, BamHI, BglII, SalI, PstI, HindIII) was linearized with the restriction enzume EcoRI. The reaction was performed in a total volume of 50 ul and a final concentration of 1 ug/ul plasmid DNA. 50 Units of EcoRI were added an the digestion was proved after incubation at 37° C. for three hours by agarose gel electrophores. The reaction was stopped by adding 1 ul of 0.5 M EDTA and the DNA was precipitated with a final concentration of 0.3 M sidium acetate and 3-4 volumes of ethanol at -80° C. for 30 minutes. The precipitated DNA was dissolved in 50 ul distilled water.
2 ul of plasmid DNA were mixed with 10 ul of the fragment DNA containing the V2 promoter sequence, and ligated together in a total volume of 25 ul of ligation buffer containing 2 units T4-DNA ligase and 2 mM ATP at 14° C. overnight. Thereafter the DNA was purified by phenol/chloroform extractions followed by two ethanol precipitations and dissolved in 10 ul distilled water. The resulting sticky ends of EcoRI and ApaI had to be converted into blunt ends and ligated. The blunt ends were converted by a removing reaction with the Mung bean nuclease as follows: to 25 ul DNA (1 ug/ul concentration) reaction buffer, 20 units of enzyme and a final concentration of 1% glycerol to the reaction volume of 35 ul were added. After an incubation for 30 minutes at 30 C the DNA was purified by phenol/chloroform extractions followed by two ethanol precipitations. The DNA was dissolved again in 5 ul distilled water. The resulting blunt ends were ligated together in 15 ul reaction volume containing 10× more T4 ligase then used above and 2 mM ATP at 14° C. overnight.
The ligation mixture was added to 150 ul competent bacterial cell suspension for DNA up-take. After the DNA up-take the bacterial cells were spread on LB agar plates containing 50 ug/ml ampicillin at volumes of 50 to 300 ul cell suspension per plate. The agar plates were incubated at 37° C. overnight. Single isolated bacterial colonies were screened for the presence of a plasmid containing the desired U2-promoter fragment.
3. Screening for desired plasmid containing bacterial colonies
Single colonies were picked with a toothpick and transferred to a LB-ampicillin containing tube (5 ml). The tubes were incubated overnight at 37° C. by shaking rapidly. A mini plasmid preparation of each grown bacterial suspension was made. The different resulting plasmid was proved by digestion with both restriction endonucleases EcoRI and HindIII. Two molecules were found, a 400 bp fragment containing the U2 promoter sequence and the plasmid of 2,700 bp. The digestion was analysed by agarose gel electrophoresis. The resulting plasmid was isolated from the bacterial cells.
4) Insertion of the neomycine selection marker.
The plasmid pBPV-342-12 (commercially available from ATCC) was digested with the endonucleases EcoRI and BamHI. Two molecules were isolated, one containing the MT promoter together with the neomycin selection gene of 4,000 bp and the plasmid of 10,000 bp.
The plasmid resulting from (3) above was linearized with EcoRI and ligated together with the 4,000 bp fragment containing the MT-promoter together with the neomycin selection gene. The resulting sticky ends were also converted into blunt ends and ligated together as described above.
After bacterial transformation, colony selection and mini plasmid preparation, the resulting plasmids were analysed by a digestion with the restriction enzymes EcoRI and HindIII. Two DNA molecules were isolated, a 400 bp fragment and a 6,700 bp fragment.
5) Ligation of the BglII-BglII fragment
The plasmid resulting from (4) above was linearized with BglII. The 2.3 kb-BglII-BglII fragment was ligated together with the linearized plasmid. Bacterial colonies were analysed to find the resulting plasmid. The plasmid-DNA was digested with EcoRI and two resulting fragments were obtained, a 700 bp fragment (containing the promoter and a part of the HBV-sequence) and a 8,700 bp fragment (containing the rest of the HBV-sequence, MT-neo and plasmid).
6) Alterations within the HBV-sequence
The plasmid resulting from (5) above was digested with the endonucleases BglII and MstII. Two molecules were generated, one of 300 bp containing part of the pre-S sequence and the other (9,100 bp) which was eluted as described above. This 9,100 bp fragment was ligated to another BglII/MstII 216 bp fragment (sequence
__________________________________________________________________________= AGATCTACAGCATGGGGCAGAATCTTTCCACCAGCAATCCTCTGGGATTCTTTCCCGACCA BglII S1 CCAGTTGGATCCAGCCTTCAGAGCAAACACCGCAAATCCAGATTGGGACTTCAATCCCAA CAAGGACACCTGGCCAGACGCCAACAAGGTAGGAGCTGGAGCATTCGGCCTGGGTTTCAC CCCACCGCACGGAGGCCTTTTGGGGTGGAGCCCTCAGG) MstII__________________________________________________________________________
coding for an altered pre-S 1 gene sequence.
The desired plasmid was digested with EcoRI and two resulting fragments were isolated, a 616 bp fragment and a 8,700 bp fragment.
EXAMPLE 5
Isolation of the H2K Promoter
The H2K promoter was isolated as an EcoRI/BglII fragment (2 kb) from psp65H2 (available from Exogene).
Isolation of the agpt selection marker
The fragment containing the methallothionoin promoter and the agpt-selection gene was isolated by digestion of the plasmid pMSG (available from Pharmacia) with the restriction enzyme EcoRI as a 3.6 kb fragment.
All other plasmid constructions were made in similar ways by combining fragments containing the necessary components and employing desired oligonucleotides and adapter sequences (where necessary).
EXAMPLE 6
Transfection of Mammalian Cells with Constructs of the Present Invention
In order to achieve secretion of substantial amounts of the HBV peptides encoded by constructs of the present invention, mammalian cells must be transfected with both the construct of the present invention and a construct which will express entire S protein. The cotransfection was performed in two steps (i.e., a separate transfection for each construct) or in a single step (i.e., one transfection using preparation of both constructs). Cotransfection was confirmed either by use of different selection markers on the two constructs or by detection of secretion of expression products of both constructs by immunoassay.
Alternatively, a sequence encoding the HBV peptide sequence of the present invention and a separate sequence encoding the entire S protein could be combined in a single construct.
EXAMPLE 7
General Procedures
General procedures useful in practicing the present invention may be found in (1) Methods in Enzymology, volume 152, "Guide to Molecular Cloning Techniques," ed. Berger and Kimmel (Academic Press 1987), and (2) Maniatis et al., "Molecular Cloning: A Laboratory Manual," (Cold Spring Harbor Laboratory 1982), both of which are incorporated herein in their entirety be reference. Specific techniques employed are described below.
1) Digestion with Endonuclease and Isolation of Fragments
The restriction endonucleases used were: BglII, BamHI, HindIII, EcoRI, XbaI, MstII, XhoI, PflMI, commercially available from Gibco/BRL with their respective restriction buffers (10×).
Unless otherwise indicated, restriction digests were performed and fragments were isolated as follows. Reactions typically contained 1-5 ug DNA.
distilled water was added to the DNA in an eppendorf tube to a final volume of 8 ul
1 ul of the appropriate 10× digestion buffer was added
1 ul (containing 5-10 U) restriction enzyme was added and mixed carefully
the reaction tube was incubated for 1 hour at 37° C.
digestion was stopped by adding 0.5 M EDTA (pH 8.0) to a final concentration of 10 mM
if the DNA was analysed directly on a gel, 1 ul of gel-loading dye III (Maniatis) was added, mixed and the sample was loaded into the slots of a 0.8% agarose gel.
The agarose gel normally contains 0.8% agarose 1 x running buffer (TBE, Maniatis). Where a fragment (about 100-1000 bp) was isolated from an agarose gel the agarose was increased to 1.2 to 1.4%.
2) Competent Bacterial Cells
From a dense overnight culture, 1 ml of the bacterial cell suspension was added to 100 ml fresh growth medium (L-broth). The cells were grown at 37° C. to a density of OD 600 =0.7 which was reached within 2 hours with vigorous shaking in a 500 ml Erlenmeyer flask. Growth was atopped by chilling the culture on ice for 10 minutes. From this culture, 3 ml were taken for harvesting the exponential bacterial cells at 3,000 rpm for 5 minutes. The cells were resuspended in 1.5 ml of 50 mM CaCl 2 in 10 mM Tris, pH 8.0, and incubated on ice for another 15 minutes. The cells were harvested once more by centrifugation at 3,000 rpm for 5 minutes and resuspended in 200 ul of 50 mM CaCl 2 in 10 mM Tris, pH 8.0, and used directly.
3) Transformation of Competent Bacterial Cells
The DNA to be transformed was suspended in 10 mM Tris, pH 7.5, 1 mM EDT 70 ul and added to the 200 ul bacterial cell suspension for DNA take-up. The mixture was incubated on ice for 30 minutes and then 1 ml L-broth was added. The mixture was incubated at 42° C. for 2 minutes and at 37° C. for 40 minutes.
After the incubation, the cells were spread on agar plates containing 50 ug ampicillin/ml agar at volumes of 50-300 ul cell suspension per plate. The agar plates were incubated at 37° C. overnight. After this incubation period, single isolated bacterial colonies were formed.
4) Plasmid DNA Isolation
1 liter of plasmid-bearing cells was grown to 0.5 OD 600 in L-broth and amplified for 20 hours with 200 ug/ml chloramphenicol. The culture was then centrifuged at 4,000 rpm for 20 minutes in JA-10 rotor, 4° C. The pellet was resuspended in 18 ml cold 25% sucrose, 50 mM Tris, pH 8.0 , transferred to a 250 ml Erlenmeyer flask and kept on ice. 6 ml 5 mg/ml lysozyme in 250 mM Tris, pH 8.0 was added and the mixture was left to stand 10-15 minutes. 6 ml 250 mM EDTA, pH 8.0, was added, mixed gently and incubated for 15 minutes on ice. 30 ml detergent (0.01% Triton X-100; 60 nM EDTA, pH 8.0; 50 mM Tris, pH 8.0) was added and the mixture was incubated for 30 minutes on ice. After incubation, the mixture was centrifuged at 25,000 rpm 90 minutes in SW28 rotor, 4° C.
Pronase was added to supernatant fluid to 250 ug/ml and incubated 30 minutes, 37° C. The solution was extracted with phenol once with 1/2 volume phenol equilibrated with 10 mM Tris, pH 8.0, 1 mM EDTA. The aqueous layer was removed. Sodium acetate was then added to a final concentration of 300 mM, followed by the addition of 3 volumes cold 100% ethanol and thorough mixing. The mixture was stored at -20° C. overnight.
The mixture was thawed and centrifuged. The pellet was resuspended in 6 ml 10 mM Tris, 10 mM EDTA, pH 8.0, 9.4 g CsCl and 0.65 ml of 6 mg/ml ethidium bromide were added and the volume was brought up to 10 ml with sterile double-distilled water. The 10 ml alignots were put into Beckman heat-sealable gradient tubes and centrifuged, 50,000 rpm, 48 hours in Ti70.1 Beckman rotor.
Plasmid bands were visualized with UV and removed with syringe and 18 gauge needle by piercing the side of the tube. Ethidium bromide was removed from the plasmid fractions by 3 successive extractions with equal volumes of isobutanol. Fractions were then (1) dialyzed against one 2-liter lot of 10 mM Tris, pH 7.4, 1 mM EDTA, pH 7.5, 5 mM NaCl for 2 hours or more at 4° C.; and (2) phenol extracted once with 1/3 volume phenol equilibrated as above. Sodium acetate was then added to a final concentration of 300 mM, followed by addition of two volumes of 100% ethanol. Precipitate formed at -20° C. overnight, or at -70° C. for 30 minutes.
5) Mini-Plasmid Preparation
1 ml of an overnight bacteria culture was put into an eppendorf tube and centrifugated for 20 minutes. The supernatant was removed. 100 ul of 50 mM glucose, 25 mM Tris (pH 8.0), 10 mM EDTA (pH 8.0) was added to the pellet, mixed by vortex and incubated for 5 minutes at room temperature. 200 ul of 0.2 N NaOH, 1% SDS was added, mixed by vortex and incubated for 5 minutes on ice. 150 ul 3 M Sodium acetate (pH 4.8) was added, mixed by vortex and incubated for 5 minutes on ice. After centrifugation for 5 minutes at 13,000 rpm the supernatant was decanted into a fresh eppendorf tube. 3 volumes of 100% ethanol were supplemented, mixed well and incubated for 30 minutes at -80° C., then centrifuged for 10 minutes at 13,000 rpm. The ethanol was removed, the pellet washed with 70% ethanol, lyophilized and dissolved in 20 ul distilled water. 5 ul of this plasmid DNA solution were used directly for restriction analysis.
6) Nick Translation
Nick translation was performed according to Rigby et al., J. Mol. Biol., Vol. 113, pp. 237-251, 1977, which is incorporated herein by reference. The reaction mixture for 32 P-labeling of DNA contained 0.5 ug of a HBV fragment, in a total volume of 30 ul with 50 mM Tris, pH 7.8, 5 mM MgCl 2 , 10 mM mercaptoethanol, 0.1 mM dATP, 0.1 mM dGTP, 0.1 mM dTTP, 50 uCi 32 P-dCTP, 10 units DNA polymerase I, 3 ul of a 2×10 -5 fold dilution of 1 mg/ml DNase I and is incubated for 90 minutes at 15° C., yielding 3×10 6 to 12×10 6 total cpm, i.e. 1×10 7 to 5×10 7 cpm/ug DNA.
7) Southern Blot Analysis
To characterize the organization within the host cell genome of the vectors of this invention, chromosomal DNA from cell lines producing particles of this invention were isolated and digested with the appropriate restriction enzyme(s) and analysed by the method of Southern (J. Mol. Biol., Vol. 98, pp. 503-517, 1975), which is incorporated herein by reference, using a 32 P-labeled DNA probe. Following digestion of the chromosomal DNA (20 ug) with the restriction enzyme BglII, the resulting fragments were separated by 0.7% agarose gel electrophoresis. Thereafter, the DNA was denatured by exposing to 366 nm UV light for 10 minutes and by incubation in a solution of 0.5 M NaOH and 1 M NaCl for 45 minutes. The gels were neutralized by incubation in 0.5 M Tris, 1.5 M NaCl, pH 7.5 for 60 minutes. The DNA was transferred to a nitrocellulose filter by soaking in 3 M NaCl, 0.3 M Sodiumcitrate (20 x SSC) for 20 hours through the gel by covering the top of the nitrocellulose filter with a staple of dry paper towels. The nitrocellulose filter was kept for 2 hours in a vacuum oven at 80° C. A radioactive DNA probe from the BglII fragment of the pHBV (2.3 kb) was prepared by nick translation.
For hybridization with the DNA probe, the nitrocellulose filter was sealed in a plastic bag containing 10 ml of prehybridization mixture: 50% formamide, 5 x SSC, 50 mM Sodiumphosphate, pH 7.0, 5 x Denhardt's solution, 250 ug/ml denatured salmon sperm DNA. The filter was incubated in this mixture for 4 hours at 45° C., after which the pre-hybridization mixture was replaced by the hybridization mixture: 50% formamide, 5 x SSC, 20 mM Sodiumphosphate, pH 7.0, 1 x Denhardt's solution, 100 ug/ml denatured salmon sperm DNA, 5×10 5 cmp/ml 32 P-probe. The filter, after incubating in the hybridization mix for 18 hours at 45° C., was washed three times, 5 minutes each, in 0.1 x SSC, 0.1% SDS at 50° C. The filter was dried at 60° C. for 10 minutes and exposed to two X-ray films (XAR-5, KODAK) between two intensifying screens and kept at -80° C. The first X-ray film is developed after 3 days' exposure; the second film after 7 days' exposure.
8) Preparation of Mammalian Cells and DNA Precipitate for Transfection
The recipient cells (C127 or CHO-cells available from ATCC) were seeded in normal growth medium (DMEM+10% Fetal Calf Serum, Glycose and Glutamin) into petri-dishes (1-2×10 6 cells per dish, ¢ 10 cm) at day 1. The next day the medium was removed (4 hours before the DNA precipitate was added onto the cells), and the cells were washed twice with 1×PBS. Then 8 ml DMEM without FCS were added. 4 hours later the DNA precipitate (prepared as described below) was added to the cells. Again after 4 hours the medium was removed, 3 ml of Glycerol-Mix (50 ml 2 x TBS buffer, 30 ml glycerol, 120 ml distilled water) were added. The Glycerol-Mix was immediately removed after an incubation at 37° C. for 3 minutes and the cells were washed with 1 x PBS. The cells were cultivated overnight with 8 ml of DMEM with 10% FCS.
After 48 hours, the cells were recovered from the dish by treating with Trypsin-EDTA-Solution (0.025% Trypsin+1 mM EDTA). Afterwards, to remove the Trypsin-EDTA the cells were washed with 1 x PBS, suspended in DMEM with 10% FCS and distributed into 24 costar-well-plates (cells from one dish into four 24-well-plates). When the cells had grown well, selection medium was added (concentration 0.5-1 mg/ml of neomycin, or xanthine: 250 μg/ml, hypoxanthine: 15 μg/ml (or adenine: 25 μg/ml), thymidine: 10 μg/ml, aminopterine 2 μg/ml mycophenolic acid: 25 μg/ml for eco-gpt, for example). The medium was changed every week. The first growing cell colonies were seen after 2 weeks.
To 10 ug of plasmid DNA and 20 ug of carrier-DNA (salmon-sperm DNA, calf-thymus DNA) TE-buffer (10 mM Trix-HCl, 1 mM EDTA, pH 7.05) was added to a final volume of 440 ul and mixed together with 60 ul 2 M CaCl 2 . Then the same amount of 2 x TBS (Hepes 50 mM, NaCl 280 mM, Na 2 HPO 4 1.5 mM, pH 7.05) was added and mixed well. The precipitation solution was incubated for 30 minutes at 37° C. and added directly to the cells which should be transfected.
EXAMPLE 8
Culturing of Transfected Cells to Secrete Protein
The selected cells are treated for further cultivation in normal growth medium as described in section 8.
EXAMPLE 9
F) Preparation of the Adjuvant of Purified Particles
To the desired concentration of antigen particles suspended in sterile saline, 1:10,000 volume Thimerosol, 1/10 volume of filter-sterilized 0.2 M Al K(SO 4 ) 2 :12 H 2 O were added. The pH was adjusted to 5.0 with sterile 1 N NaOH and the suspension was stirred at room temperature for 3 hours. The alum-precipitated antigen was recovered by centrifugation for 10 minutes at 2,000 rpm, resuspended in sterile normal saline containing 1:10,000 Thimerosol and aliquoted under sterile conditions.
EXAMPLE 10
Tables III-X give some of the results of ELISA analysis of immunogenic particles of the present invention as described below:
Table III: shows the ELISA data of the purified HBs antigen particle produced from any HBV sequence construct of the present invention including the pre-S 1 region with total deletion of pre-S 2 and deletions upstream of the pre-S 2 ATG and the S region with deletion of the S ATG and downstream the S ATG through the XBaI site (e.g. the construct of FIG. I-1) with the anti-pre-S 1 monoclonal antibody MA 18/7. The fractions 9-15 (FIG. 11) were pooled after CsCl sedimentation.
Table IV: shows the ELISA data of the purified HBS antigen particle produced from any HBV sequence construct of the present invention including the pre-S 1 region with total deletion of pre-S 2 and deletions upstream of the pre-S 2 ATG and the S region with deletion of the S ATG and downstream the S ATG through the XBaI site (e.g., the construct of FIG. 1A) with the anti-pre-S 2 monoclonal antibody MQ 19/10. The fractions 9-15 (FIG. 11) were pooled after CsCl sedimentation.
Table V: shows the ELISA data of the purified HBs antigen particle produced from an HBV sequence construct of the present invention including the pre-S 2 region with none of the pre-S 1 region and deletions upstream of the S ATG and downstream of the S ATG through the XBaI site, and the S region with deletion of the S ATG (e.g. the construct of FIG. 2A) with the anti-pre-S 1 monoclonal antibody MA 18/7. The fractions 9-15 (FIG. 12) were pooled after CsCl sedimentation.
Table VI: shows the ELISA data of the purified HBS antigen particle produced from an HBV sequence construct of the present invention including the pre-S 2 region with none of the pre-S 1 region and deletions upstream of the S ATG and downstream of the S ATG through the XBaI site, and the S region with deletion of the S ATG (e.g. the construct of FIG. 2A) with the anti-pre-S 2 monoclonal antibody MQ 19/10. The fractions 9-15 (FIG. 12) were pooled after CsCl sedimentation.
TABLE III______________________________________ ELISA MeasurementCsCl-gradient Monoclonal Antibody MA 18/7______________________________________Fraction No. 9-15 (pooled) E.sub.492 = 0.839______________________________________
TABLE IV______________________________________ ELISA MeasurementCsCl-gradient Monoclonal antibody MΩ 19/10______________________________________Fraction No. 9-15 (pooled) E.sub.492 = 0.000______________________________________
TABLE V______________________________________ ELISA MeasurementCsCl-gradient Monoclonal Antibody MA 18/7______________________________________Fraction No. 9-15 (pooled) E.sub.492 = 0.000______________________________________
TABLE VI______________________________________ ELISA MeasurementCsCl-gradient Monoclonal Antibody MΩ 19/10______________________________________Fraction No. 9-15 (pooled) E.sub.492 = 1.028______________________________________
Table VII: shows the ELISA data of the purified HBs antigen particle produced from any HBV sequence construct of the present invention including the pre-S 1 region with total deletion of pre-S 2 and deletions upstream of the pre-S 2 ATG and the S region with deletion of the S ATG (e.g., the construct of FIG. 6B) with the anti-pre-S 1 monoclonal antibody MA 18/7. The fractions 9-15 (FIG. 11) were pooled after CsCl sedimentation.
Table VIII: shows the ELISA data of the purified HBs antigen particle produced from any HBV sequence construct of the present invention including the pre-S 1 region with deletions upstream of the pre-S 2 ATG with deletion of the S ATG (e.g., the construct of FIG. 6B) with the anti-pre-S 2 monoclonal antibody MQ 19/10. The fractions 9-15 (FIG. 11) were pooled after CsCl sedimentation.
Table IX: shows the ELISA data of the purified HBs antigen particle produced from an HBV sequence construct of the present invention including the pre-S 2 region with none of the pre-S 1 region and deletions upstream of the S ATG and the S region with deletion of the S ATG (e.g., the construct of FIG. 7B) with the anti-pre-S 1 monoclonal antibody MA 18/7. The fractions 9-15 (FIG. 12) were pooled after CsCl sedimentation.
Table X: shows the ELISA data of the purified HBs antigen particle produced from an HBV sequence construct of the present invention including the pre-S 2 region with deletions upstream of the S ATG with deletion of the S ATG (e.g., the construct of FIG. 7B) with the anti-pre-S 2 monoclonal antibody MQ 19/10. The fractions 9-15 (FIG. 12) were pooled after CsCl sedimentation.
TABLE VII______________________________________ ELISA MeasurementCsCl-gradient Monoclonal Antibody MA 18/7______________________________________Fraction No. 9-15 (pooled) E.sub.492 = 1.273______________________________________
TABLE VIII______________________________________ ELISA MeasurementCsCl-gradient Monoclonal Antibody MΩ 19/10______________________________________Fraction No. 9-15 (pooled) E.sub.492 = 0.000______________________________________
TABLE IX______________________________________ ELISA MeasurementCsCl-gradient Monoclonal Antibody MA 18/7______________________________________Fraction No. 9-15 (pooled) E.sub.492 = 0.000______________________________________
TABLE X______________________________________ ELISA MeasurementCsCl-gradient Monoclonal Antibody MΩ 19/10______________________________________Fraction No. 9-15 (pooled) E.sub.492 = 0.985______________________________________
Table XI shows the ELISA data of purified HBs antigen particles produced by construct including the entire pre-S 1 -pre-S 2 -S region under control of the LTR region of rous sarcoma virus after stimulation with stimulating substances (e.g. PMA) and the additional cotransfection with S (FIG. 13).
TABLE XI______________________________________ ELISA MeasurementCsCl-gradient Monoclonal Antibody MA 18/7______________________________________Fraction No. 9-15 (pooled) E.sub.492 = 0.125______________________________________
Figure XIV shows the characterisation of the particles derived from gene constructs according to table III (FIG. 1A) and table V (FIG. 2A) cotransfected in C127 after purification in the CsCl gradient. The fraction collected had a smaller volume.
Table XII shows the serotyping of particles according to FIG. 1A having the S sequence done in the Pettenkofer Institute.
TABLE XII______________________________________Results:adw/ayw: positive______________________________________
From the foregoing, it will be obvious to those skilled in the art that various modifications in the above-described compositions and methods can be made without departing from the spirit and scope of the invention. Accordingly, the invention may be embodied in other specific forms without departing from the spirit or essential characteristics thereof. Present embodiments, therefore, are to be considered in all respects as illustrative and not restrictive, the scope of the invention being indicated by the appended claims rather than by the foregoing description, and all changes which come within the meaning and range of equivalency of the claims are therefore intended to be embraced therein. | HBV surface antigen particles, prepared by recombinant DNA technology are described, said particles being composed of epitopes from the group of surface peptides and/or core peptide of non-A, non-B hepatitis virus, hepatitis virus A and/or hepatitis virus B. Respective particles are especially characterized by a composition of different epitopes selected from pre-S and S peptides. There are also described DNA-sequences, plasmids and cell lines coding for respective HBV surface antigen particles as well as a new vaccine containing the same. | 8 |
FIELD OF THE INVENTION
The present invention relates to alignment fiducials fabricated on the semi-conductor die of surface emitting devices for optoelectronic applications.
A BACKGROUND OF THE INVENTION
A light emitting device often utilizes a double heterostructure in which an active region of III-V semiconductor is sandwiched between two oppositely doped III-IV compounds. By choosing appropriate materials for the outer layers, the band gaps are made to be larger than that of the active layer. This procedure, well known to one of ordinary skill in the art, produces a device that permits light emission due to recombination in the active region, but prevents flow of electrons or holes between the active layer and the higher band gap sandwiching layers due to the differences between the conduction band energies and the valence band energies, respectively. Light emitting devices can be fabricated to emit from the edge of the active layer, or from the surface. Typically, the first layer of material, the substrate, is n-type Indium Phosphide (InP) with an n-type buffer layer, which, again, is Indium Phosphide normally. The active layer is often a quaternary material and is p-type. This active layer is, for example, Indium Gallium Arsenide Phosphide (InGaAsP) with a p-type cladding layer for example, again, Indium Phosphide disposed thereon. Such a structure is made to have light emission which is orthogonal to the plane of the layer of the active region, rather than from a direction which is parallel to the plane of the active layer, which is an edge emitting device.
One area of optoelectronics which has seen a great deal of activity in the recent past is passive alignment. Silicon waferboard, which utilizes the crystalline properties of silicon for alignment of optical fibers, as well as passive and active optical devices has gained a great deal of acceptance in the recent past. One technique for aligning an optoelectronic device to an optical fiber and other passive/active elements is the use of alignment pedestals for x, y planar registration and standoffs for height registration. By virtue of the sub-micron accuracy of photolithography, the etching of alignment fiducials has proven to be a viable alignment alternative. By effecting alignment in a passive manner, the labor input to the finished product can be reduced, resulting in increased performance at a reduction in labor input during the alignment process. One example of such a passive alignment scheme can be found in U.S. Pat. No. 5,163,108 to Armiento, et al., the disclosure of which is specifically incorporated by reference herein. The reference to Armiento, et al., makes use of an alignment notch on the chip of the device with alignment pedestals disposed on the silicon waferboard. This structure is for aligning an optical fiber array to an array of light emitting devices.
While the reference to Armiento, et al., is a viable approach to aligning an edge emitting device, there is a need in the industry to make use of surface emitting devices. An alternative approach to the structure disclosed in the reference to Armiento, et al. which does enable the passive alignment of surface emitting devices is as disclosed in U.S. patent application Ser. No. 08/674,770 to Boudreau, et al., the disclosure of which is specifically incorporated herein by reference. While the reference to Boudreau, et al. makes use of a passive alignment member which is fabricated from silicon and is used to effect the alignment of an optoelectronic device which is either surface emitting or detecting, there is a need for alignment of the surface emitting/detecting device through precision notches directly on the device.
Accordingly, what is needed is an alignment technique for aligning a surface emitting/detecting optoelectronic device by way of alignment fiducials directly on the die of the device.
SUMMARY OF THE INVENTION
The present invention is drawn to a surface emitting optoelectronic device having grooves on the die which effect alignment in the x direction for planar registration and planar pad areas on the die which effect alignment in the z direction for height registration to properly align the focal plane of the device to an optical fiber, for example. As will be discussed herein, the invention of the present disclosure has applicability to many different devices, with the common element being the etching properties of the quaternary active layer. To this end, the present invention is drawn to surface emitting devices which use a quaternary material as is described herein. The axial alignment is effected with respect to the mesa of a light emitting diode. This alignment is done in a two step etch process which makes use of the etching properties of various materials which are used in the fabrication of conventional light emitting devices.
In a first etch, the mesa of the surface emitting light emitting diode (SLED) is defined. A groove is etched during this etch step for passive alignment. To this end, during a first photolithographic step, a layer of SiO 2 is deposited and patterned, whereby the mesa is etched at a particular point on the die, and grooves are also etched for alignment purposes. Through this first step, the groove is etched relative to the mesa center to within a tolerance on the order of 0.3 microns. This groove is etched about the perimeter of the mesa, and for reasons set forth herein one of the grooves is used to locate an ohmic contact. A second etch step is carried out thereafter to define the depth of the groove, on either side of the mesa, while maintaining the precision of the distance from the edge of the groove to the mesa center. This second etch is for the express purpose of making the groove deeper so that the x alignment pedestals disposed on the silicon waferboard only contact the device along the alignment fiducials established by the first etch. For the first and second etches, smooth planar pads are preserved for registration to the stand-offs disposed on the silicon waferboard. That is, portions of the original wafer surface are protected from etching for the express purpose of providing subsequent Z height registration for the focal plane of the device. These smooth planar pad areas are for the express purpose of providing sufficient area for the standoffs to maintain z-height registration during the complete movement of x and y alignment.
One novel feature of the invention at the present disclosure lies in the use of materials in effecting the alignment grooves of the die. To this end, a layer of quaternary materials (Indium Gallium Arsenide Phosphide--InGaAsP) is used for both the active layer and in the etching process. To this end, this layer is a common material used in light emitting diodes for the active layer between the cladding layers of the LED. However, in the second etch, the etchant is chosen so that it will not etch the quaternary material. Thereby through the proper placement of the quaternary material, relative to the center of the mesa, the proper distance from the center of the mesa to the alignment groove is maintained while the other layers of material readily etch to the proper depth. That is, the quaternary material serves as the etch-stop for the second etch for the depth of the alignment fiducials.
Furthermore, the device of the present disclosure in its preferred embodiment is envisioned to function in an optical transceiver for example as is disclosed in U.S. Patent Application Numbers (TWC Docket No. 17182L as well as TWC Docket No. 17213). Some of the advantages of the use of the structure of the present invention in the transceiver packages of the referenced Patent Applications will be elaborated upon infra.
OBJECTS, FEATURES AND ADVANTAGES
It is an object of the present invention to have on-chip alignment for optoelectronic surface emitting devices.
It is a feature of the present invention to have an alignment groove etched along an outer edge of the chip with the groove being aligned to the center of the mesa at a prescribed distance.
It is an advantage of the present invention that the alignment groove effects x axis registration as well as registration of the focal plane of the light emitting device in the z direction.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1a is cross-sectional view of the preferred embodiment of the invention of the present disclosure, showing the deeper grooves formed in the second etch step for x-direction alignment to side pedestals on silicon waferboard.
FIG. 1b is a cross-sectional view of the preferred embodiment of the present disclosure showing the grooves etched in the first etch step with the one of the ohmic contacts in the groove as well as the landing pads on either side of the mesa.
FIG. 2 is a top view of the back side of the preferred embodiment of the present disclosure.
FIGS. 3-5 are cross sectional views of the fabrication steps for fabricating the mesa structure surface emitting LED of the present disclosure.
DETAILED DESCRIPTION OF THE INVENTION
FIG. 1 shows a cross sectional view of the preferred embodiment of the present disclosure, a surface emitting light emitting device, such as an SLED 101. While the preferred embodiment is an SLED, it is clear that the passive alignment scheme of the present invention could be applied to other surface emitting devices such as a vertical cavity surface emitting laser (VCSEL). An integral lens 102 is formed by techniques well known in the art, as is disclosed in U.S. Pat. No. 4,797,179, to Watson, et al., the disclosure of which is specifically incorporated herein by reference. The light emitting diode mesa structure is shown at 103, with the notch regions at 104 for passive alignment of the LED 101 to a silicon waferboard or other suitable optical bench well known to one of ordinary skill in the art (not shown).
The grooves 104 and planar pads 201, 202 in FIG. 2, are used in passive alignment in the x and z directions through the use of pedestals and standoffs, respectively, again well known to one of ordinary skill in the art. In the preferred embodiment of the present disclosure, the registration of the die is effected as follows. The registration of the device for proper passive alignment is effected in an exemplary manner as follows. The device is set down on the landing pads 201, 202 which are used for z height registration to the fiducial standoffs on the silicon waferboard (not shown). The die is thereafter moved in the -y-direction (using the axis shown in FIG. 2 for reference). Upon abutting the side surface 207 to the y pedestal, or side pedestal, on the silicon waferboard, the die is then moved in the -x-direction. This motion is continued until the x pedestal, or side pedestal abuts the edge or side surface shown at 204. In this manner, the proper location of the die in the x-direction by the use of the side of the edge 204 and the y-direction through the side of the edge 207 effects planar registration of the die. The standoffs which make contact to the landing pads 201 and 202 assure proper z-height registration for proper alignment to the focal point. Further understanding of the use of alignment fiducials to include pedestals and standoffs can be found in U.S. Pat. No. 5,163,108 to Armiento, et al., as referenced above as well as U.S. patent application Ser. No. 08/674,770 to Boudreau, et al., the disclosures of which are incorporated herein by reference.
Turning to FIG. 3, the processing steps for fabricating the preferred embodiment of the present disclosure are discussed. The substrate 301 is preferably n-type Indium Phosphide (InP). A layer of n-type Indium Phosphide is used as the buffer layer 305, 405 in FIG. 4. The quaternary layer 306, 406 serves as the active layer of the LED, and a p-type cladding layer 307, 407 and p-type cap layer 308, 408 are disposed thereon. The p-type cladding layer is also Indium Phosphide while the cap layer is also quaternary material, Indium Gallium Arsenide Phosphide. A layer of silicon dioxide is deposited though standard technique on top of the cap layer, with a layer of photoresist disposed thereon. The photoresist is exposed and the exposed photoresist is removed by standard technique in areas which are to remain unprotected to pattern the silicon dioxide, to effect the features 302, 303 used in the first etching step. Thereafter, the etching is effected using non-selective etchant, typically containing hydrobromic acid, to reveal the mesa structure of FIG. 4. This etching step effects an etch on the order of 4 to 5 microns, as far down as the substrate, however normally only down to the buffer layer. During the first etching step, the mesa shown at 205 in FIG. 2 is defined. Additionally, during this first etch step, which is at a depth on the order of 4-5 microns, the side notch or edge having a flat surface 206 and a side surface 203 is also defined. This notch or edge effected in this first etch is about the perimeter of the die and serves as the basis for the deeper grooves used for alignment to the side pedestals. The notch or edge shown at 206 will have the added metallization that makes n-type contact 20 co-planar with the metallization for the p-type contact 209 of the mesa structure 205. The first etch also reveals notches 104 shown in FIGS. 1 and 2 which has a side surface 204. The second etch effects the final depth of the grooves 104 having side surfaces 204. Again, this etch is deeper than that of the first etch step, as is described herein. Finally, the side surfaces 207 are effected during a cleaving step. Accordingly, the first etch disposes a perimeter about the die at a depth on the order of 4-5 microns, as well as reveals the mesa shown at 205 in FIG. 2 and enables the p and n contacts to be on the same side of the die. After completing the first etching step, a layer of silicon dioxide is deposited as shown at 402. This layer is used to protect the mesa structure, and is patterned by standard photolithographic technique in a manner so that it does not come to the edge of the previous etch. This layer of SiO 2 has an edge which does not cover the quaternary layer 406 which is used as an etch-stop layer in the second etching step. The edge of the SiO 2 403 is preferably 3-10 μm to the edge of the quaternary layer 406. The second etch, which is slightly re-entrant by design, assures that the alignment fiducial edge 404 is the point of contact with the alignment pedestal on the silicon waferboard. That is, as can be seen in FIG. 5, the edge of layer 406 which is originally located in the first etch, is maintained with great precision (to within an accuracy of 0.3 μm) relative to the mesa center and abuts the side pedestal on the silicon waferboard.
In the first etching step, the distance between the edge 404 and the center of the active region of the mesa structure of the LED is defined. This distance is shown as "d" in FIG. 4 and is on the order of 100 μm. The distance "d" establishes very precisely, the distance from the center of the active region of the LED to the alignment notch 104 by virtue of photolithographic etching techniques to submicron accuracy. A further etch is required in order to have a notch 104 which is deep enough for proper alignment in the x direction for planar alignment and the z direction for focal point registration. Furthermore, one of the regions of the notch in the first etch step is used for same-side p- and n-type contacts 209, 208 to enable the elimination of wire bonding. To this end, through standard electroplating techniques, the n contact 208 is disposed on the surface 206 of one of the "shallower" notches defined by 203, 206, while the p-contact 209 is disposed as shown most clearly in FIG. 2. These contacts 209, 208 are made co-planar in this process. The layer 402 of silicon dioxide 403 comes nearly to the edge (shown in FIG. 4 at 403) of the quaternary layer 402 and close to the edge 404 of the notches 104. This placement of the silicon dioxide layer 402 protects the mesa and substantially all of the quaternary layer 406 near the edge 409. However, in the subsequent etch step, a suitable etchant, typically containing hydrochloric acid, is chosen that does not etch the exposed quaternary layer 406 but, which does etch Indium Phosphide to replicate the aforementioned fiducial alignment edge 404 to the required depth. The oxide layer 402 is not deposited to the edge of the quaternary layer 406, as over-coating or completely covering the cap layer 408 or even depositing the oxide 403 in the region revealed by the first etch could potentially destroy the alignment of the notch 104 to the center of the mesa 205.
The first etching step shown in final form in FIG. 4 has the proper position or alignment of the notch 104 for pedestal registration to the waferboard, but is not deep enough. Accordingly, a deeper etch is required, on the order of 12-20 microns (shown in FIG. 4). This subsequent etch is carried out with a suitable etchant which will not etch the edge 404 of the quaternary layer 406 which is formed in the first etching step. The edge 404 of this quaternary layer 406 is relatively sharp, and this precision as well as the precision relative to center of the mesa 205 is maintained by taking the oxide layer 402 in the subsequent etching step to nearly the edge 404 of the quaternary layer 406, but not to the edge 404. Re-entrant etching using the appropriate quaternary layer 406 to resist etching, thereby maintains the precision but at the same time enables the proper depth to be etched as described above. This is an important advantage of the preferred embodiment of the present invention. The sides of the deep notches 104 the chip are used for x alignment only in this device.
This gives an accuracy of well under 1 μm, typically 0.3 μm given this invention. In the y direction, the alignment is determined by the accuracy of the scribing operation, on the order of 2 μm. The wet chemical etch that is used to replicate the initial etched edge deeper into the wafer is sensitive to the crystal structure and is not readily adaptable to the y direction alignment. Therefore, in the y direction, in the preferred embodiment of the present disclosure, a scribing operation is effected in order to provide the side surfaces shown in FIG. 2 at 207. While this is the preferred embodiment of the present disclosure, it is possible that an etching step or a combination of an etching and scribing step could be used in order to effect this side surface for y direction registration to a side pedestal on the silicon waferboard.
In the Z direction, the stand-offs rest on the original surface in the smooth planar pads 201, 202. These planar areas are protected by SiO 2 during all etching steps. These pads are designed to be large enough in the x and y directions (reference coordinate axes in FIG. 2) to accommodate the full range of movement of the z-axis standoffs (disposed on the waferboard, not shown) on the surface of the LED during the alignment process. Finally, while the preferred etch-stop is a quaternary material 206 with a wet etchant referenced referenced above, it is clear that the invention can be modified in both etch-stop material and etch in order to effect the relative alignment of the present invention. For example, instead of InGaAsP, and a solution containing hydrochloric acid as the etchant, the etch stop could be SiO 2 and methane-hydrogen reactive ion etching (RIE) could be used to effect the etching.
Thereafter, the p and n contacts 209, 208 in layers are effected through standard metallization and lift-off techniques with a thin layer of Ti/Pt/Au disposed in the p contact opening. The metal thickness is adjusted during electroplating to bring both n and p up to the same height. This is shown in FIG. 1b. Finally, the backside processing is carried out in order to form the integral lens 102 if desired. Furthermore, in lieu of the integral lens, a hologram could be effected by known techniques or in the alternative other lens 102 elements can be use which are not integral to the chip. The device contacts are on the same side of the device in order to forego the use of wirebonds. In applications where the emitter and detector are bonded to a silicon waferboard or other suitable substrate in close proximity, the wirebonds can be and preferably must be eliminated. In this case, the contacts 209, 208 are on the chip and one notch defined by 206, 208 of the die can have the contact 208 therein. As stated, the device 101 fabricated by the disclosure herein can be flip-chip bonded to a silicon waferboard substrate requiring no wirebonds. This enables the detector and emitter to be bonded to the silicon waferboard in relatively close proximity (on the order of 750 microns). However, in order to avoid optical cross-talk, lens elements 102 will be required in order to properly couple the light to the respective optical fibers in a manner which minimizes the detrimental effects of cross-talk. The invention of the present disclosure can be used in an industry standard fiber-optic transceiver package known as the mini-MT. Further details of both the coupling and packaging can be found in U.S. patent application Ser. No. 09/031,592, filed Feb. 27, 1998, and U.S. patent application Ser. No. 09/031,585, filed Feb. 27, 1998, the disclosures of which are specifically incorporated herein by reference.
The invention having been described in detail, it is clear that modifications and variations of the present disclosure are readily apparent to one of ordinary skill in the art having had the benefit of the present disclosure. To the extent that a variation in technique for fabricating a notch on the die of a surface emitting light emitting device by selective etching using the active layer, a quaternary material, as an etch stop is within the purview of an artisan of ordinary skill in the art having had the benefit of the present disclosure, such as deemed within the scope of the present invention. | An optoelectronic apparatus has, a die having a mesa (103) with a surface emitting optical device and a metallized p-type contact (209), a planar pad (201) adjacent the mesa for Z-height registration with an optical bench, a first notch (206) having been provided by a first etch and having thereon a metallized n-type contact (208) that is coplanar with the p-type contact (209), a second notch having a side surface (204) having been provided by a second etch, the second notch to abut the optical bench along an x-axis, the first notch (206) extending to the second notch, and the die having side surfaces (207) to abut the optical bench along a y-axis, and the second notch extending to the side surfaces (207). | 6 |
CROSS REFERENCE TO RELATED APPLICATIONS
This application is a continuation-in-part of our prior application Ser. No. 694,081, filed Dec. 28, 1967, now abandoned, and our application Ser. No. 819,480 filed Apr. 25, 1969, now abandoned.
FIELD OF THE INVENTION
This invention relates to perfluoroaliphatic substituted amino compounds containing acrylic groups and the method for preparing the same.
DESCRIPTION OF THE PRIOR ART
It is well known that nonfluorinated alkyl halides of the formula
C.sub.n H.sub.2n.sub.+1 X
wherein n is an integer and X is a halogen, react with ammonia and with amines to produce various substituted amine and quaternary ammonium salts. However, in the case of fluorinated alkyl halides of the formula
C.sub.n F.sub.2n.sub.+1 --CH.sub.2 CH.sub.2 --X
wherein n and X each has the same meaning as stated above, the halides become readily dehydrohalogenated in the presence of nucleophilic agents such as various amines which include the tertiary amine to yield fluorinated olefins of the formula
C.sub.n F.sub.2n.sub.+1 --CH=CH.sub.2
summary of the invention
We have discovered that it is possible according to the method of this invention to prepare a perfluoroalkyl substituted amino compound of the formula ##STR4## wherein n is an integer from 6 to 20, m is 2 or 4, R 1 and R 2 each is hydrogen atom or a lower alkyl with 1 to 3 carbon atoms, R 3 is a hydrogen atom, an alkyl containing 1 to 20 carbon atoms, an alkenyl containing 3 to 10 carbon atoms, a cycloalkyl radical containing 3 to 12 carbon atoms, a cycloalkenyl with 5 to 12 carbon atoms, and N or O ring substituted cycloalkenyl radical containing 5 to 12 carbon atoms, an aryl, the radical of --(CHR) q --OH wherein R is a hydrogen atom or a lower alkyl containing 1 to 3 carbon atoms, and R 4 is a hydrogen atom or a methyl group, by reacting at a temperature between 0° and 200° C. and in the presence of a polymerization inhibitor and with or without a transesterification catalyst, a hydracid acceptor or a water acceptor,
a. a perfluoroalkyl amine of the formula ##STR5## wherein n, m, R 1 , R 2 and R 3 have the same meaning as stated above with
b. an acrylic compound of the formula
XCOCR.sup.4 =CH.sub.2 V.
wherein X is --Cl, --OH, --O--COCR 4 =CH 2 or an alkoxy radical with 1 to 8 carbon atoms and R 4 has the same meaning as stated above. Perfluoroaliphatic amines of the formula ##STR6## together with perfluoroaliphatic amines of the formula ##STR7## wherein R 1 and R 3 have the same meaning as stated above and n is an integer from 4 to 20 when reacted with an acrylic compound corresponding to formula V according to the process of this invention, simultaneously yield compounds having the formula ##STR8## together with compounds of the formula ##STR9## wherein R 1 , R 3 and R 4 have the same meaning as previously stated and n is an integer from 4 to 20.
DESCRIPTION OF THE PREFERRED EMBODIMENT
The perfluoroaliphatic amines suitable for this invention are prepared according to our copending United States application filed concurrently herewith, entitled "Perfluoroaliphatic Substituted Amines and the Method for Preparing the Same." It is therein disclosed that perfluoroalkyl amines of the formula ##STR10## wherein n, m, R 1 and R 2 have the same meaning as designated above and R is an alkyl containing 1 to 20 carbon atoms, an alkenyl containing 3 to 10 carbon atoms, a cycloparaffin radical containing 3 to 12 carbon atoms, a cylkoalkenyl radical containing 3 to 12 carbon atoms, an N or O ring substituted cycloakenyl radical containing 5 to 12 carbon atoms, or an aryl are prepared by reacting at a temperature in the range between 0° and 200° C. perfluoroalkyl halides of the formula
C.sub.n F.sub.2n.sub.+1 (CR.sup.1 R.sup.2).sub.m Y IX.
wherein n, m, R 1 and R 2 each has the same meaning as defined hereinabove and Y is an iodine or a bromine atom with amines of the formula ##STR11## wherein R 3 has the same meaning as stated for formula VIII. It is also disclosed therein that perfluoroaliphatic substituted amines of the formula ##STR12## and mixtures of XI with compounds of the formula are prepared in the same manner as compounds of formula VIII except that in the starting compounds of formula VIII, at least one of the radicals R 1 or R 2 is hydrogen, m is equal to 2 and n is an integer between 4 and 20. The preferred perfluoroaliphatic amines of this invention are compounds XI together with XII.
The perfluoroaliphatic amino alcohols suitable for this invention are prepared by the method disclosed according to our copending United States application filed concurrently herewith entitled, "Perfluoroaliphatic Substituted Amino Alcohols and the Method for Preparing the Same" also filed concurrently herewith. It is therein disclosed that perfluoroaliphatic substituted amino alcohols of the formula ##STR13## wherein n, m, R 1 , R 2 and R and q have the same meaning as stated above are prepared by reacting at a temperature in the range between 20° and 200° C. perfluoroalkyl halides of the formula
C.sub.n F.sub.2n.sub.+1 (CR.sup.1 R.sup.2).sub.m Y IX.
with an amino alcohol of the formula
H.sub.2 N(CHR).sub.q OH XIV.
wherein R and q have the same meaning as previously stated. It is also disclosed therein that perfluoroaliphatic substituted amino alcohols of the formula ##STR14## and mixtures of XV with compounds of the formula ##STR15## are prepared in the same manner as formula XIII compounds except that in the starting compounds of formula XIII, at least one of the radicals R 1 or R 2 is hydrogen, m is equal to 2 and n is an integer between 4 and 20. The preferred perfluoroaliphatic amino alcohols of this invention are compounds XV together with XVI.
In the reaction where X of formula V is a atom, atome, the operation is carried out in the presence of a hydracid acceptor such as the tertiary amines, for example, trimethylamine, triethylamine, tripropylamine, tributylamine, tripentylamine and pyridine.
In the case where X is the OH group, the operation is carried out in the presence of a water captor such as sulfuric acid, or a molecular sieve. The water can also be eliminated by azeotropic distillation using a solvent which is inert with respect to the reactants.
In the case where X is an alkoxy group, the operation is carried out with or without a transesterification catalyst such as acid or basic catalysts, for example, sulfuric acid, para-toluene-sulfonic acid, and acid resin, and aluminum alcoholate. The alcohol formed in the reaction medium may be retained or it may be eliminated during the reaction.
The fluorinated compounds according to the invention have interesting and varied applications. Thus, the monomers obtained can be polymerized or copolymerized with other acrylic, methacrylic, or vinylic molecules by the usual methods.
These strongly fluorinated polymers and copolymers used in solution or in dispersion, are extremely powerful oleophobic and hydrophobic agents. Their chemical stability and especially their resistance to hydrolysis makes it possible for them to assure a permanent protection to the textiles and other substrate, such as paper, leather, etc., on which they are used. They may also be added to other polymers such as, in particular, natural or synthetic elastomers, butadiene-styrene and butadiene-acrylonitrile copolymers, chloropene polymer, acrylic elastomers, etc., to improve their surface properties.
The following examples illustrate the new products according to the invention.
The following examples 1 to 7 also employ a mixture of saturated and unsaturated perfluoroaliphatic amino compounds as reported in examples 8 to 13. However, the corresponding unsaturated amino compound was added to the reaction mixture together with the saturated amino compound and the individual quantities of the saturated and unsaturated compound obtained were reported as the total amount of perfluoroaliphatic amino compound reacted. Examples 14 and 15 did not yield a mixture of compounds.
EXAMPLE 1
Acrylic chloride (5 grams, 0.055 mole) was added drop by drop and under continuous agitation to a solution of C 6 F 13 --C 2 H 4 --NH--CH 2 CH 2 OH (21 grams, 0.052 mole) and triethylamine (5 grams, 0.05 mole) in methylene chloride (60 cm 3 ), cooling the reaction vessel with an ice-water bath. After the reaction, the precipitated triethylamine chlorhydrate was filtered and ethyl ether was added to the filtrate to precipitate the triethylamine chlorhydrate remaining in solution in the methylene chloride. After filtration, the solvents were eliminated by prolonged evaporation under vaccuum. The viscous residual liquid (20 grams), which was difficult to purify, was made up of ##STR16## containing C 6 F 13 C 2 H 4 NHC 2 H 4 OCOCH=CH 2 as an impurity.
EXAMPLE 2
Acrylic chloride (6.4 grams; 0.07 mole) was added drop by drop under continuous agitation to a solution of C 6 F 13 C 2 H 4 --NH--CH 3 (26 grams; 0.069 mole), triethylamine (7 grams; 0.07 mole), and hydroquinone (0.05 grams) in methyl chloride (65 cm 3 ), cooling the reaction vessel with an ice bath. After the reaction, the precipitated triethylamine chlorhydrate was filtered, and ethyl ether was added to the filtrate to precipitate the triethylamine chlorhydrate remaining in solution in the methylene chloride. After filtration, the solvents were eliminated by evaporation under vacuum, hydroquinone was added (0.1 gram), and the residual liquid was distilled. There were thus obtained three fractions:
a. light products/1 mm HG.: 1.2 grams. This fraction was made up essentially of methylene chloride;
b. 86° C/1 mm Hg. fraction: 23.9 grams. This fraction was made up of ##STR17## c. Residue: 1.3 grams of a polymerized solid
The yield of the experiment reached 80%.
EXAMPLE 3
Acrylic chloride (15 grams; 0.16 mole) was added drop by drop, under continuous agitation, to a solution of C 6 F 13 --C 2 H 4 --NH--C 4 H 9 (63 grams; 0.15 mole), triethylamine (16 grams; 0.16 mole), and hydroquinone (0.1 grams) in methylene chloride (160 grams), cooling the reaction vessel with an ice bath. After reaction, the triethylamine chlorhydrate was filtered and ethyl ether was added to the filtrate to precipiate the triethylamine chlorhydrate remaining in solution in the methylene chloride. After filtration, the solvents were eliminated by evaporation under vacuum, hydroquinone was added (0.1 gram) and the residual liquid with a boiling point near 100° C under a pressure of 5×10 - 1 mm Hg. (64.5 grams). This liquid was made up of an acrylamide with the formula
C.sub.6 F.sub.13 C.sub.2 H.sub.4 N(C.sub.4 H.sub.9)COCH=CH.sub.2
the yield of the experiment reached 90%.
EXAMPLE 4
A mixture of C 6 F 13 --C 2 H 4 --NH--CH 3 (18.85 grams; 0.05 mole), methyl acrylate (21.5 grams; 0.25 mole), and phenylenediamine (0.1 gram) was held at 90°-95° for 4 hours. As they arrived at the head of the distillation column, the light products passing between 62° and 80° were eliminated. After four hours the residual liquid was separated into fractions:
a. 80° fraction, 16 grams, made up of methyl acrylate;
b. 75°/1 mm fraction, 1.6 grams;
c. 82°-85°/1 mm fraction, 18.1 grams, made up of C 6 F 13 C 2 H 4 (CH 3 )COCH=CH 2 .
The yield of the experiment is 84%.
EXAMPLE 5
In a flask, acrylyl chloride (4.33 grams; 0.048 mole) was added drop by drop under constant stirring to a solution of C 8 F 17 --C 2 H 4 --NH n --C 4 H 9 (24.7 grams; 0.047 mole) triethylamine (4.7 grams; 0.047 mole), and hydroquinone (0.1 gram) in methylene chloride, (50 grams). During the addition of acrylyl chloride, the flask was cooled in an ice-water bath. Towards the end of the addition, the triethylamine hydrochloride formed was filtered off and ethyl ether was added to the filtrate in order to precipitate the triethylamien hydrochloride which remained in solution. After a second filtration, the solvents were eliminated by evaporation under vacuum. Hydroquinone (0.1 gram) was then added to the viscous residual liquid, which was distilled in a molecular distillation equipment. Thus, C 8 F 17 --C 2 H 4 --N(n C 4 H 9 )--CO--CH=CH 2 (20.9 grams; 0.0365 mole) was obtained. It distilled over at 105°-115°/0.1 mm.
Conversion rate of C 8 F 17 --C 2 H 4 --N(n C 4 H 9 )--CO--CH=CH 2 is 77%.
EXAMPLE 6
In a flask, acrylyl chloride (6.1 grams; 0.066 mole) was added drop by drop under constant stirring to a solution of C 6 F 13 --C 2 H 4 --NH 2 (24.1 grams; 0.066 mole), triethylamine (6.7 grams; 0.066 mole), and hydroquinone (0.1 gram) in methylene chloride (65 grams). During the addition of acrylyl chloride, the flask was cooled in an ice-water bath. Towards the end of the addition, the triethylamine hydrochloride formed was filtered off, and ethyl ether was added to the filtrate in order to precipitate the triethylamine hydrochloride which remained in solution. After a second filtration, the solvents were eliminated by evaporation under vacuum. Finally, hydroquinone (0.1 gram) was added to the residual liquid, which was distilled, and yielded C 6 F 13 --C 2 H 4 --NH--CO--CH=CH 2 (20.3 grams; 0.0485 mole) distilling at 100°-110°/0.5 mm Hg.
Conversion rate for C 6 F 13 --C 2 H 4 --NH--CO--CH=CH 2 is 74%.
EXAMPLE 7
In a flask, acrylyl chloride (4.8 grams; 0.050 mole) was added drop by drop under constant stirring to a solution of C 10 F 21 --C 2 H 4 --NH--CH 3 (28.85 grams; 0.050 mole), triethylamine (5.05 grams; 0.05 mole), and hydroquinone (0.1 gram) in methylene chloride (50 grams). During the addition of acrylyl chloride the flask was cooled in an ice-water bath. Towards the end of the addition, the triethylamine hydrochloride formed was filtered off and ethyl ether was added to the filtrate in order to precipitate the triethylamine hydrochloride which remained in solution. After a second filtration, the solvents were eliminated under vacuum. Finally, hydroquinone (0.1 gram) was added to the residual solid, which was sublimed at 140°-160°/0.1 mm Hg. Thus ##STR18## was obtained (26.2 grams; 0.0415 mole).
EXAMPLE 8
Acrylic chloride (6.4 grams) was added drop by drop under constant agitation to a solution of C 5 F 11 =CH--CH 2 --NH--CH 3 (26 grams), C 6 F 13 --C 2 H 4 --NH--CH 3 (17.6 grams), triethylamine (7 grams) and hydroquinone (0.05 grams) in methylene chloride (65 cm 3 ) with the reaction vessel cooled by an ice bath. After completion of the reaction, the triethylamine chlorhydrate remaining in the methylene chloride would precipitate. After filtration, the solvents were eliminated by evaporation under vacuum, hydroquinone (0.1 gram) was added, and the remaining liquid distilled. Three fractions were obtained:
a. Volatile Products/1 mm Hg.: weighing 1.2 gram contained mostly methylene chloride.
b. 86° C/1 mm Hg. fraction: weighing 23.9 grams contained 14% ##STR19## c. Residue: an unidentified polymerized solid weighing 1.3 gram.
Yields were 11% for ##STR20## and 69% for ##STR21##
EXAMPLE 9
C 5 F 11 --CF=CH--CH 2 --NH--CH 3 (18 grams), C 6 F 13 --C 2 H 4 --NH--CH 3 (1.9 gram), methylacrylate (21.5 grams) and p-phenylenediamine (0.1 gram) were held at 90°-95° C for 4 hours. As they arrived at the head of the distillation column, the volatile products passing between 62° and 80° were eliminated. After 4 hours, the residual liquid was separated into four fractions:
a. 80° C fraction, weighing 16 g. was methyl acrylate
b. 75° C/1 mm Hg. fraction: 1.6 gram.
c. 82°-85° C/1 mm Hg. fraction: 17.3 grams contained 13% ##STR22## and 87% ##STR23##
Yields were 11% for ##STR24## and 73% for ##STR25##
EXAMPLE 10
Acrylic chloride was added drop by drop into a flask containing a solution (28 grams) of 86% C 9 F 19 CF=CH--CH 2 --NH--CH 3 , and 14% C 10 F 21 --C 2 H 4 --NH--CH 3 , triethylamine (5.05 grams) and hydroquinone (0.13 gram) in methylene chloride (50 grams). During the addition of the acrylyl chloride, the flask was cooled by an ice bath. At the end of the addition, the triethylamine chlorhydrate formed was filtered and ethyl ether was added to the filtrate in order to precipitate any triethylamine chlorhydrate remaining in solution. After a second filtration, the solvents were eliminated under vacuum. Hydroquinone (0.1 gram) was added to the solid residue which had sublimed at 140°-160° C at 0.1 mm Hg. There was thus obtained 25.5 grams of a mixture of 89%. ##STR26## and 11% ##STR27##
EXAMPLE 11
Acrylyl chloride (7.2 grams) was added drop by drop under constant stirring to a reaction flask containing a mixture (30.8 grams) of C 5 F 11 CF=CH--CH 2 --NH--C 4 H 9 and C 6 F 13 --C 2 H 4 --NH--C 4 H 9 and triethylamine (7.5 grams) in methylene chloride (65 cm 3 ). During the addition of the acrylyl chloride, the reaction flask was cooled with an ice bath. As soon as the acrylic chloride was introduced, a white solid consisting of triethylamine chlorhydrate appeared. The solid was filtered and ethyl ether added to the filtrate to eliminate any triethylamine chlorhydrate remaining in the methylene chloride. After filtration, the solvents were evaporated and molecular distillation of the remaining viscous liquid was carried out at 5×10 - 2 mm Hg. A mixture of 13.4 grams C 6 F 13 --C 2 H 4 --N--(C 4 H 9 )--CO--CH=CH 2 (Yield = 37.5%) and 14.5 grams C 5 F 11 CF=CH 2 --N-- (C 4 H 9 )--CO--CH=CH 2 (Yield -- 42.5%) was obtained.
EXAMPLE 12
Acrylyl chloride (4.33 grams) was added drop by drop under constant stirring to a reaction flask containing a mixture (24.2 grams of 0.047 mole C 7 F 15 --CF=CH--CH 2 --NH--nC 4 H 9 and 0.025 mole C 8 F 17 --C 2 H 4 --NH--nC 4 H 9 , triethylamine (4.7 grams) and hydroquinone (0.1 gram) in methylene chloride (50 grams). During the addition of the acrylyl chloride, the flask was cooled with an ice bath. At the end of the addition, the triethylamine formed was filtered and ethyl ether was added to the filtrate to precipitate any triethylamine chlorhydrate remaining in the solution. After a second filtration, the solvents were eliminated by evaporation under vacuum. Hydroquinone (0.6 grams) was added to the remaining viscous liquid which was then distilled by means of molecular distillation apparatus. 20.5 grams of a mixture coming off at 105°-115°/0.1 mm Hg. containing ##STR28## ##STR29## were obtained.
EXAMPLE 13
Acrylic chloride (11.7 grams) were added drop by drop with constant agitation to a solution (49 grams) containing 0.042 mole ##STR30## and hydroquinone (0.19 grams) in methylene chloride (120 grams) while maintaining a temperature below 5° C by means of an ice bath. After the reaction, the triethylamine precipitate was filtered and ethyl ether was added to the filtrate in order to precipitate any triethylamine chlorhydrate remaining in the methylene chloride. After filtration, the solvents were removed by vacuum evaporation. Hydroquinone (0.1 gram) was added to the resinal liquid which was distilled yielding two fractions.
a. 90°-100°/0.05 mm Hg. fraction: weighing 46 grams contained 34% ##STR31## (Yield = 28.8%) and 66% ##STR32## Yield = 56.28%).
EXAMPLE 14
In a flask, acrylyl chloride (4.8 grams; 0.050 mole) was added drop by drop under constant stirring to a solution of C 6 F 13 (C 2 H 4 ) 2 NH--CH 3 (20.0 grams; 0.050 mole), triethylamine (5.06 grams; 0.050 mole), and hydroquinone (0.1 gram) in methylene chloride, the flask was cooled in an ice-water bath. Towards the end of the addition, the triethylamine hydrochloride formed was filtered off, and ethyl ether added to the filtrate in order to precipitate the triethylamine hydrochloride which remained in solution. After a second filtration, the solvents were eliminated by evaporation under vacuum. Finally, hydroquinone (0.1 gram) was added to the residual liquid, which was distilled in a molecular distillation apparatus. Thus ##STR33## (17.4 grams; 0.038 mole) boiling at 100°-110°/0.1 Hg. was obtained.
Conversion rate for ##STR34## is 76%.
EXAMPLE 15
In a flask, acrylyl chloride (3.5 grams; 0.036 mole) was added drop by drop under constant stirring to a solution of C 8 F 17 (C 2 H 4 ) 2 NH 2 (17.6 grams; 0.036 mole), triethylamine (3.65 grams; 0.036 mole), and hydroquinone (0.1 gram) in methylene chloride (25 grams). During the addition of the acrylyl chloride, the flask was cooled in an ice-water bath. Towards the end of the addition, the triethylamine hydrochloride formed was filtered off, and ethyl ether added to the filtrate in order to precipitate the triethylamine hydrochloride which remained in solution. After a second filtration, the solvents were eliminated by evaporation under vacuum. Hydroquinone (0.1 gram) was added to the residual solid, which was sublimed between 140° and 160° under 0.1 mm Hg. Thus, C 8 F 17 (C 2 H 4 ) 2 NH--CO--CH=CH 2 (15.1 grams; 0.028 mole) was obtained.
Conversion rate for C 8 H 17 (C 2 H 4 ) 2 NH--CO--CH=CH 2 is 77%. | This invention comprises perfluoroaliphatic substituted amino compounds of the formula ##STR1## wherein n is an integer from 6 to 20, m is 2 or 4, R 1 and R 2 each is hydrogen atom or a lower alkyl with 1 to 3 carbon atoms, R 3 is a hydrogen atom, an alkyl containing 1 to 29 carbon atoms, an alkenyl containing 3 to 10 carbon atoms, a cycloalkyl radical containing 3 to 12 carbon atoms, a cycloalkenyl with 5 to 12 carbon atoms, an N or O ring substituted cycloalkenyl radical containing 5 to 12 carbon atoms, an aryl, the radical --(CHR) 1 --OH wherein R is a hydrogen atom or a lower alkyl containing 1 to 3 carbon atoms, and R 4 is a hydrogen atom or a methyl group and the method for preparing the same. This invention also comprises perfluoroaliphatic substituted amino compounds of the formula ##STR2## and mixtures of products of formula II with compounds of the formula ##STR3## and the method for preparing the same. The compounds are strong oleophobic and hydrophobic agents. | 2 |
FIELD OF THE INVENTION
[0001] The present invention relates to a reverser for a timepiece, in particular for a self-winding watch.
BACKGROUND OF THE INVENTION
[0002] French patent no. 1,079,576 published in 1954 relates to a self-winding device for a clockwork mechanism. In said device, a winding wheel drives an output wheel, depending on the direction of rotation thereof, in one or the other of the following ways:
either by means of a pinion which it carries and which acts as a satellite engaged with another pinion meshing with the output wheel, or by meshing with another wheel likewise carrying a pinion which forms another satellite engaged with another pinion meshing with the output wheel.
[0005] German patent no. 952,879 published 1956 describes a freewheel clutch for a self-winding watch. This clutch comprises two input wheels driven in opposite directions by a winding wheel. Each of these input wheels is integral with a pinion around which a satellite forming a pawl which is mounted on a lower wheel can move. The two lower wheels mesh with one another and one of them is integral with an output wheel. Thus, depending on the direction of rotation of the winding wheel, the output wheel is driven:
either by a first input wheel, a first pinion, a first satellite and a first lower wheel which forms a first satellite carrier, said first lower wheel being engaged with a second lower wheel which is integral with the output wheel; or by a second input wheel, a second pinion, a second satellite and the second lower wheel, the latter carrying the second satellite carrier and being integral with the output wheel.
[0008] In other words, in this German patent, each satellite is mounted on a lower wheel, the lower wheels serve as a satellite carrier, they mesh with one another, always rotate in opposite directions and just one, the one rotating in the rewinding direction of the spring barrel, is integral with the output wheel.
BRIEF DESCRIPTION OF THE INVENTION
[0009] The above-stated mechanisms in particular have the drawback of occupying a large amount of space and it would seem that despite almost 60 years having elapsed since the publication thereof, no-one has yet managed satisfactorily to solve this problem of space.
[0010] The applicant's inventors have now succeeded in developing a substantially smaller reverser.
[0011] One particular feature of this mechanism, in comparison with the clutch of the above-stated German patent DE 952,879, is that it comprises just one satellite carrier for its two satellites.
[0012] More specifically, the reverser according to the invention comprises:
a first input moving part comprising a first receiving toothing and integral with a first transmission toothing; a second input moving part comprising a second receiving toothing and integral with a second transmission toothing; at least one first satellite cooperating with the first transmission toothing in such a manner as to be capable of rotating in a single direction; at least one second satellite cooperating with the second transmission toothing in such a manner as to be capable of rotating in a single direction, said satellite being freely rotatable relative to the first satellite; a satellite carrier carrying the second satellite; an output moving part integral with the satellite carrier;
[0019] and is characterised in that the first satellite is also carried by the single satellite carrier.
[0020] The reverser according to the invention furthermore has the advantage of allowing the majority of the component parts thereof to be arranged coaxially.
[0021] The advantageous features of the reverser according to the invention are stated in the following points:
[0022] Notably, the first and second input moving parts of the reverser are coaxial.
[0023] Likewise, the first and second transmission toothings of the reverser may be internal toothings. In this case, the first and second satellites may preferably also be coaxial.
[0024] According to another embodiment of the present invention, the satellite carrier of the reverser is coaxial with the output moving part.
[0025] Notably, the satellite carrier of the reverser is coaxial with the first input moving part and/or the second input moving part.
[0026] According to another embodiment of the present invention, the first and second satellites of the reverser may have separate pivot axes.
[0027] Notably, the first and second satellites are arranged to cooperate with their respective second transmission toothing so as to rotate in opposite directions.
[0028] Likewise notably, the first and second input moving parts, the satellite carrier and the output moving part are all coaxial.
[0029] According to still another embodiment of the present invention, the satellite carrier carries a plurality of pairs of first and second satellites.
[0030] The invention also relates to a self-winding watch comprising a reverser as previously defined, said watch furthermore possibly comprising a mechanism capable of driving the input moving parts in rotation in opposite directions.
BRIEF DESCRIPTION OF THE DRAWINGS
[0031] Other characteristics and advantages of the invention will now be described in detail in the following description which is provided with reference to the appended drawings which show schematically:
[0032] FIG. 1 : a diagram showing the principle of operation of the mechanism which, for the purposes of the present invention, is designated “reverser”;
[0033] FIG. 2 : a reverser according to a first embodiment of the invention in perspective and sectional view from above;
[0034] FIG. 3 : the reverser of FIG. 2 in sectional side view;
[0035] FIG. 4 : a cutaway detail of FIG. 2 ;
[0036] FIGS. 5 and 6 : illustrations of the operation of the reverser according to FIGS. 2 to 4 ;
[0037] FIG. 7 : a reverser according to a second embodiment of the reverser according to the invention in sectional side view;
[0038] FIG. 8 : a variant of the reverser of FIG. 7 in sectional side view;
[0039] FIGS. 9 to 11 : a variant of the reverser according to the first embodiment of the invention, in plan view, sectional side view and sectional side and perspective view;
[0040] FIGS. 12 and 13 : an illustration of the directions of rotation of the parts of the reverser according to the first embodiment of the invention;
[0041] FIGS. 14 and 15 : diagrams showing locking or otherwise of satellite-input wheel drive; and
[0042] FIGS. 16 to 21 : various methods for attaching a satellite to a satellite carrier.
DETAILED DESCRIPTION OF THE INVENTION
[0043] In the present specification, a “reverser” is taken to mean a mechanism which makes it possible to convert the rotational movements in two directions of a moving part into a rotational movement in a single and invariable direction.
[0044] The principle of operation such a mechanism is illustrated by FIG. 1 .
[0045] FIGS. 2 and 3 show a first embodiment of the reverser according to the present invention. As can be seen, said reverser comprises a shaft 1 , a lower end of which comprises a lower toothing 2 , in order to constitute an output moving part capable of being connected in known manner, generally by a kinematic chain which is not shown, to the spring barrel of a timepiece to be rewound.
[0046] On the shaft 1 , above the lower end thereof, a satellite carrier 3 has been driven on from above which assumes the overall form of a hollow cylinder provided with a portion which forms a disc in such a manner that the plane of said disc is perpendicular to the longitudinal axis of the hollow cylinder. The s bottom of said cylinder abuts against the lower toothing 2 of the shaft 1 . The portion which forms the disc is passed through longitudinally by a peg 4 onto the upper part of which has been driven a first satellite 5 . The peg 4 is freely rotatable relative to the portion which forms the disc of the satellite carrier 3 and about an axis parallel to that of the hollow cylinder.
[0047] On the top of the hollow cylinder of the satellite carrier 3 , a first input wheel 6 is freely rotatably mounted and held in place axially by a locking ring 7 , the lower face of which first input wheel comprises a first internal toothing 8 which may be the toothing of a ring attached in known manner (welding, brazing etc.). Said internal toothing 8 is provided to cooperate with the first satellite 5 .
[0048] On the bottom of the hollow cylinder of the satellite carrier 3 , a second input wheel 12 is freely rotatably mounted and held in place axially by a locking ring 9 , the upper face of which second input wheel comprises a second internal toothing 10 which may be the toothing of a ring attached in known manner (welding, brazing etc.).
[0049] A second satellite 11 is arranged freely rotatably about the peg 4 , being sandwiched between, from below, the second input wheel 12 and, from above, the portion which forms the disc of the satellite carrier 3 . Said second satellite 11 is provided to cooperate with the second internal toothing 10 .
[0050] Cooperation between the satellites 5 and 11 and, respectively, the internal toothings 8 and 10 can be seen in FIG. 4 . The satellites 5 and 11 form pawls, i.e. they have teeth, the asymmetrical shape of which is provided to allow them to rotate only in a single direction. Such a shape is well-known to a person skilled in the art and is represented, in particular, in FIGS. 3 and 4 of the above-stated French patent (parts numbered 4 and 5 ). As a variant, it is possible to provide that it is the teeth of the internal toothings 8 and 10 which form pawls, like the teeth of wheels 30 and 40 in FIG. 1 of the above-stated German patent.
[0051] It is also possible to provide for both an internal toothing and the teeth of a satellite to have specific shapes which cooperate with one another in order to permit rotation in one direction and locking in another direction, as taught by Swiss patent no. 321,237.
[0052] Thus, for a given direction of rotation of the internal toothing 8 , meshing and therefore driving of the satellite 5 in rotation is possible, whereas in the other direction said satellite locks.
[0053] Likewise, for a given direction of rotation of the internal toothing 10 , meshing and therefore driving of the satellite 11 in rotation is possible, whereas in the other direction said satellite locks.
[0054] The unidirectional satellites 5 and 11 are arranged in reversed manner and they are not identical, such that one input wheel can only rotate in one direction and the other can only rotate in the opposite direction. More particularly, the shape of the teeth of the two satellites 5 and 11 is reversed so as to ensure rotation in one direction and locking in the other direction.
Operation
[0055] Operation of the reverser according to the invention is illustrated in FIGS. 5 and 6 .
[0056] Upstream of the reverser according to the invention there is provided a geartrain which compels the input wheels 6 and 12 to rotate in opposite directions.
[0057] In FIG. 5 , the shaft 1 is provided to rotate only in the usual direction of the hands of a watch, or “clockwise” direction. The first input wheel 6 is driven in counter-clockwise direction and must therefore have no effect on the shaft 1 . To achieve this, when said input wheel rotates it drives the first internal transmission toothing 8 , which is engaged with the first satellite 5 . The latter is arranged appropriately such that rotation of the internal toothing 8 , and therefore of the toothed wheel 6 , allows the satellite to mesh with the internal toothing 8 . Rotation of the latter will then bring about rotation of the satellite 5 and of the peg 4 about the longitudinal axis of the latter. Such rotation proceeds independently of the satellite carrier 3 and has no effect on it. The satellite 5 is said to rotate “in thin air”.
[0058] At the same time, the second input wheel 12 rotates in the opposite direction to that of the input wheel 6 , that is to say in the one direction in which the shaft 1 can rotate. The arrangement or orientation of the satellite 11 is such that it cannot mesh with the second internal transmission toothing 10 integral with the input wheel 12 and consequently, it cannot rotate about itself and locks. It is then driven in rotation by the second internal toothing 10 , not about the longitudinal axis of the peg 4 , but about the longitudinal axis of the shaft 1 . In this rotational movement, the satellite 11 then drives the peg 4 in rotation and therefore the assembly of the satellite carrier 3 together with the shaft 1 integral with the latter. Accordingly, the input wheel 12 , the second internal toothing 10 , the satellite 11 , the peg 4 , the satellite carrier 3 and the shaft 1 behave as if they were just a single part.
[0059] FIG. 6 shows the reverse situation. This time, it is the input wheel 6 which rotates in the direction in which the shaft 1 is intended to rotate. The satellite 5 cannot mesh with the first internal transmission toothing 8 . Locking which prevents the satellite 5 from rotating about itself therefore occurs. Rotation of the input wheel 6 then brings about rotation of the satellite 5 , the peg 4 , the satellite carrier 3 and the shaft 1 about the longitudinal axis of the shaft 1 . In this case, the input wheel 6 , the first internal toothing 8 , the satellite 5 , the peg 4 , the satellite carrier 3 and the shaft 1 behave as if they were just a single part.
[0060] Thus, whatever the direction of rotation of the input wheels 6 and 12 , the shaft 1 is always driven in rotation in the same direction.
[0061] FIGS. 9 to 11 show a variant of the reverser according to the invention, in which the input wheels 6 and 12 are attached by means of bushes 19 and 20 integral with the shaft 1 , the satellites, here six in number, rotating freely relative to the satellite carrier and being axially confined on one side by the satellite carrier and on the other side by an input wheel 6 or 12 .
[0062] FIGS. 7 and 8 show a second embodiment of the present invention which differs from the first embodiment as follows:
[0063] the first and second transmission toothings are no longer internal toothings but external toothings 13 and 14 , for example provided on pinions integral with the first and second input wheels 6 and 12 ; and
[0064] the first and second satellites 5 ′, 11 ′ are no longer coaxial: they are offset angularly, preferably diametrically opposed on the portion which forms a disc of the satellite carrier 3 .
[0065] These differences aside, the reverser operates in the same way as in the first embodiment, the assembler of the mechanism merely needing to ensure that the asymmetrical teeth of the satellites are appropriately oriented.
[0066] In FIG. 7 , it can be seen that the satellites 5 ′ and 11 ′ are formed by a single part with one portion forming a peg passing through the portion which forms the disc of the satellite carrier. The bottom (satellite 5 ′) or the top (satellite 11 ′) of the respective peg is provided with a washer to keep the respective satellite 5 ′ or 11 ′ on the satellite carrier 3 .
[0067] In FIG. 8 , it can be seen that the satellites 5 ″, 11 ″ are mounted pivotably about studs 15 , 16 driven into holes provided in the portion which forms the disc of the satellite carrier 3 .
[0068] In FIGS. 14 and 15 , it can be seen that when the external toothings 13 , 14 rotate in a first direction S1, locking of the satellites 11 ′, 11 ″ occurs whereas when the external toothings 13 , 14 rotate in a second direction S2, they drive the satellites 11 ′, 11 ″ in rotation.
[0069] In general and whatever the embodiment, the satellite carrier carries, as can be seen in FIGS. 5 and 6 , a plurality of first satellites and a plurality of second satellites and preferably, for reasons of balancing, as many first satellites as second satellites. At this point, it should be noted that increasing the number of satellites is generally useful for reducing play during a reversal in direction. Consequently, adjusting the number of satellites relative to the number of teeth makes it possible to reduce (or alternatively to increase) backlash (i.e. play) during a reversal in direction as required.
Upstream of the Reverser
[0070] As previously stated, a mechanism is provided for driving the input wheels 6 and 12 in rotation in opposite directions.
[0071] In order to achieve this, a person skilled in the art may consider any appropriate mechanism, in particular a geartrain such as that shown in FIGS. 12 and 13 .
[0072] A winding pinion 17 driven in rotation by the self-winding weight (not shown) meshes with the first input wheel 6 . At the same time, this pinion 17 meshes with a transfer pinion 18 which itself meshes with the second input wheel 12 . The toothing of the shaft 1 meshes with an output wheel 21 which thus always rotates in the same direction.
Other Variants
[0073] FIGS. 16 to 21 show variants for attaching satellites to a satellite carrier, with axial limitation of satellite displacement ( FIGS. 19 to 21 ) or without such limitation ( FIGS. 16 to 18 ; in this case, axial displacements are limited on either side by the satellite carrier and an input wheel). | A reverser for a timepiece including a first input moving part having a first receiving toothing and integral with a first transmission toothing, a second input moving part having a second receiving toothing and integral with a second transmission toothing, a first satellite cooperating with the first transmission toothing configured to rotate in a single direction, a second satellite cooperating with the second transmission toothing configured to rotate in a single direction, the satellite being freely rotatable relative to the first satellite, a satellite carrier carrying the second satellite and an output moving part integral with the satellite carrier in which the first satellite is carried by the satellite carrier. | 6 |
REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation of U.S. patent application Ser. No. 12/203,047, filed Sep. 2, 2008, which claims priority to U.S. Provisional Patent Application Nos. 60/969,452 filed Aug. 31, 2007 and 61/083,839 filed Jul. 25, 2008, and to PCT International Patent Application PCT/NZ2008/000225 filed Sep. 1, 2008, and is a continuation-in-part of U.S. patent application Ser. No. 11/745,993 filed May 8, 2007, now U.S. Pat. No. 7,649,086, which claims priority to U.S. Provisional Patent Application Nos. 60/746,682 filed May 8, 2006 and 60/869,057 filed Dec. 7, 2006.
FIELD OF THE INVENTION
[0002] The present invention relates to lignin and other products, such as xylose, xylitol, furfural, fermentable sugars, cellulose and hemi-cellulose products isolated from plant materials, methods for isolating such products from plant materials, and compositions containing such plant-derived products.
BACKGROUND
[0003] Mounting global energy demands have dramatically increased the cost of fossil-fuel-based energy sources and petrochemicals. And, the environment has been harmed, perhaps irreparably, in an effort to meet this demand by discovery and extraction of fossil-fuel feedstocks, and by processing of those raw feedstocks to produce ever increasing amounts of fuel, petrochemicals, and the like. Petrochemicals furthermore provide the majority of raw materials used in many plastics and chemical industries. The present invention is directed to providing isolated, plant-derived, renewable and sustainable compositions that have multiple utilities and that provide renewable and sustainable substitutes for fossil-fuel derived and petrochemical feedstocks.
[0004] Lignin is a complex, high molecular weight polymer that occurs naturally in plant materials, and is one of the most abundant renewable raw materials available on earth. Lignin is present in all vascular plants and constitutes from about a quarter to a third of the dry mass of wood. It is covalently linked to hemicellulose in plant cell walls, thereby crosslinking a variety of plant polysaccharides. Lignin is characterized by relatively high strength, rigidity, impact strength and high resistance to ultra-violet light and, in wood, has a high degree of heterogeneity, lacking a defined primary structure.
[0005] Lignin molecules are generally large, cross-linked macromolecules and may have molecular masses in excess of 10,000 in their native form in plant material. The degree of lignin polymerization in nature is difficult to determine, since lignin is fragmented during extraction. Various types of lignin have been characterized and described, with the lignin properties generally depending on the extraction methodology. There are three monolignol monomers, which are methoxylated to various degrees: p-coumaryl alcohol, coniferyl alcohol, and synapyl alcohol. These monomers are incorporated in lignin polymers in the form of phenylpropanoids p-hydroxyphenyl (H), guaiacyl (G), and syringyl (S). Different plants exhibit different proportions of the phenylpropanoids.
[0006] The polyphenolic nature of lignin and its low toxicity, together with many additional properties (such as its dispersing, binding, complexing and emulsifying, thermal stability, specific UV-absorbing, water repellent and conductivity characteristics), make it an attractive renewable replacement for toxic and expensive fossil fuel-derived polymer feedstocks. Unlike synthetic polymers, lignin is biodegradable in nature. In spite of its biodegradability, lignin is known to be one of the most durable biopolymers available.
[0007] Large quantities of lignin are produced as a by-product of the pulp and paper industry. Despite its unique and desirable characteristics as a natural product with multiple beneficial chemical, physical and biological properties, and its abundance, lignin isolated from plant materials remains largely under-exploited. The heterogeneity and low reactivity of lignin recovered from waste effluent produced by the pulp and paper industry has resulted in limited industrial utilization of this highly abundant and renewable natural product.
[0008] Lignin is recovered from sulfite or Kraft wood pulping processes as lignosulfonates containing significant amounts of contaminants. The recovered lignin molecules lack stereoregularity, with repeating units being heterogeneous and complex. In general, lignin obtained as a by-product of the Kraft process (referred to as Kraft lignin) requires further processing and/or modification, as described in U.S. Pat. Nos. 5,866,642 and 5,202,403, in order to increase its reactivity and to allow its use in the formation of higher value products. Kraft lignin preparations contain a mixture of lignin sulfonate and degraded lignin, together with numerous decomposition products, such as sugars, free sulfurous acid and sulfates. The phenolic structures of the Kraft lignin are highly modified and condensed. The sulfite process for wood treatment produces a water soluble sulfonated lignin preparation that contains a high content of sugars, sugar acids and sugar degradation products, as well as resinous extractives and organic constituents with multiple coordination sites. The costs associated with the purification and functionalization required to make these low grade lignin preparations useful have limited their utilization in high value application markets.
[0009] The use of organic solvents for lignin extraction prior to carbohydrate hydrolysis as disclosed, for example, in U.S. Pat. Nos. 4,764,596, 5,788,812 and 5,010,156, was shown to improve the quality of the resulting lignin, but the use of a catalyst in combination with various types of solvents under severe conditions often produced lignin having altered reactivity (McDonough (1992) TAPPI Solvent Pulping Seminar, Boston, Mass., The Institute of Paper Science and Technology ; Pan and Sano (2000) Holzforschung 54:61-65; Oliet et al. (2001) J. Wood Chem. Technol. 21:81-95; Xu et al. (2006) Industrial Crops and Products 23:180-193).
[0010] The reactivity of lignin depends mainly on the presence and frequency of aliphatic, phenolic hydroxyl and carbonyl groups, which varies depending on the lignin source and the extraction process used to obtain the lignin. The average molecular weight and polydispersity of lignin in the preparation also has a great impact on its reactivity.
[0011] As demonstrated in the many attempts to replace phenol with lignin in the formation of phenol-based resins, the low reactivity of the lignin means that only a small amount of phenol can be displaced without affecting the mechanical and physical properties of the final resin (çetin and Özmen (2002) Int. J. Adhesion and Adhesives 22:477-480; çetin and Özmen (2003) Turk. J. Agric. For. 27:183-189; Sellers et al. (2004) For. Prod. J. 54:45-51). Similar difficulties are encountered when lignin is employed in other types of applications. For example, the thermostability of lignin used to produce carbon fibers by spinning, as described in U.S. Pat. No. 6,765,028, and the carbonization of the resulting lignin fibers, are largely influenced by the method of lignin extraction and the origin and composition of the lignin (Kadla et al. (2002) Carbon 40:2913-2920).
[0012] When acidic ethanol-extracted lignin was used as a polyol for the experimental preparation of polyurethane (PU), replacement of 35% to 50% of the PU resin was achieved without compromising the integrity of the lignin-based PU film (Vanderlaan and Thring (1998) Biomass and Bioenergy 14:525-531; Ni and Thring (2003) Int. J. Polymeric Materials 52:685-707). Smaller ratios of replacement of PU resin (<10%) have been achieved by direct blending of soda lignin in pre-formed PU resin (Ciobanu et al. (2004) Industrial Crops and Products 20:231-241).
[0013] Polymer blending is also a convenient method to develop lignin based products with desirable properties. (See, e.g., Kubo and Kadla (2003) Biomacromolecules 4(3):561-567; Feldman et al. (2003) J. Appl. Polym. Sci. 89:2000-2010; Alexy et al. (2004) J. Appl. Polym. Sci. 94:1855-1860; Banu et al. (2006) J. Appl. Polym. Sci. 101:2732-2748) The efficiency and quality of the polymer blend is normally closely related to the chemical and physical properties of the lignin preparation, such as monomer type(s), molecular weight and distribution, which depends on the origin of the lignin and method used for its extraction, isolation and harvesting.
[0014] Upgrading lignin through chemical functionalization has been shown to be a good strategy for the successful incorporation of plant-derived lignins in high value products. However, these reactions are costly when low grade or low reactivity lignin is used as the substrate for chemical modification. Large amounts of reactants are required, together with longer reaction times and higher temperatures, to achieve relatively low rates of transformation of low grade and low reactivity lignins. This adds to the cost of the lignin feedstock and reduces its desirability for use in various types of industrial processes.
SUMMARY OF THE INVENTION
[0015] In one aspect, the present invention provides isolated, high grade lignin polymers derived from plant materials, as well as methods for isolating lignin from plant materials, compositions comprising the high grade lignin polymers and methods for using such lignin polymers in high value products. The disclosed lignin is more suitable for use as a feedstock for making downstream products than lignin extracted from plant materials using alternative methods, such as acid or alkaline extraction or steam explosion techniques, and has distinct properties compared to lignin polymers isolated from plant materials using alternative techniques.
[0016] The plant material employed in the disclosed methods for producing a high grade isolated lignin product is preferably a lignocellulosic plant material selected from the group consisting of: woody or herbaceous materials, agricultural and/or forestry plant materials and residues, and dedicated energy crops. In some embodiments, the plant material comprises a hardwood material, and in some embodiments the plant material comprises a coppicable hardwood material, such as a coppicable shrub. In certain embodiments, the plant material employed comprises a material selected from a group consisting of Salix (e.g., Salix schwerinii, Salix viminalis ), Poplar, Eucalyptus , Mesquite, Jatropha, Pine, switch grass, miscanthus, sugar cane bagasse, soybean stover, corn stover, rice straw and husks, cotton husks, barley straw, wheat straw, corn fiberwood fiber, oil palm (e.g., Elaeis guineensis, Eiaeis oleifera ) frond, trunk, empty fruit-bunch, kernels, fruit fibers, shell and residues of oil palm materials, and combinations thereof. Additional plant materials may be used. The present invention contemplates isolated lignin and other extraction products derived from any of these materials, and downstream products comprising lignin and other extraction products derived from any of these materials.
[0017] In some embodiments, plant materials comprising a higher proportion of syringyl (S)-lignin compared to guaiacyl (G)-lignin are preferred for processing to recover high grade isolated lignin. Plant materials having a S:G lignin ratio of at least 1:1 are preferred for some applications; plant materials having a S:G lignin ratio of at least 2:1 are preferred for some applications; and plant materials having a S:G lignin ratio of at least 3:1 or about 4:1 are preferred for some applications. The present invention comprehends isolated lignin and other extraction products derived from such plant materials, as well as compositions comprising isolated lignin and other extraction products derived from such plant materials.
[0018] In one aspect, high grade lignin and other extraction products may be isolated as a product of a solvent extraction process for treating plant materials such as the process disclosed in U.S. patent application Ser. No. 11/745,993, filed May 8, 2007 and published Nov. 8, 2007 as US 2007/0259412 A1, the disclosure of which is hereby incorporated by reference in its entirety. In this aspect, lignin is isolated from a plant material in a modified ORGANOSOLV™ (aqueous ethanol solvent) extraction process that involves contacting the plant material with a solution comprising up to about 70% ethanol in water at a temperature of approximately 170° C. to 210° C. and a pressure of from about 19-30 barg for a retention time sufficient to produce a “black liquor” solution containing lignin soluble in the aqueous ethanol solvent. In another aspect, lignin may be isolated from a plant material in a modified ORGANOSOLV™ (aqueous ethanol solvent) extraction process that involves contacting the plant material with a solution comprising up to about 80% ethanol in water, in some circumstances using a solution comprising from about 60% to about 80% ethanol in water, under conditions similar to those described above.
[0019] The modified ORGANOSOLV™ extraction is preferably carried out substantially in the absence of an introduced acid catalyst. For example, the reaction mixture may contain less than 1% of an introduced acid catalyst and, according to some embodiments, the reaction mixture contains less than 0.5% of an introduced acid catalyst. In some embodiments, the modified ORGANOSOLV™ extraction process is carried out in the absence of an introduced acid catalyst.
[0020] The black liquor produced using a modified ORGANOSOLV™ extraction process as described above may be flash evaporated to remove some of the solvent, and additional solvent may be steam-stripped from the liquor. The lignin may then be precipitated, separated by filtration and/or centrifugation, and dried. As a consequence of the mild nature of the modified ORGANOSOLV™ extraction process (treatment with aqueous ethanol solvent in the substantial absence of a biocatalyst), the extracted lignin is minimally modified from its native form and contains fewer contaminants (e.g., salts, sugars and/or degradation products) than lignins produced using Kraft or sulfite processes. The lignin produced by the modified ORGANOSOLV™ extraction process thus offers much greater potential as a bio-based feedstock material for use in a variety of processes and syntheses than lignin produced during paper pulp production or from other biomass fractionation processes using catalysts and more severe extraction conditions.
[0021] High grade lignin of the present invention may thus be isolated from a plant material in a modified ORGANOSOLV™ extraction process that involves contacting the plant material with a solvent comprising up to 80% ethanol in water, in some embodiments from about 60% to 80% ethanol in water and, in some embodiments, about 70% ethanol in water. The temperature of the materials undergoing the modified ORGANOSOLV™ extraction process may be approximately 170° C. to 210° C., in some embodiments approximately 180° to 200° C., and in yet other embodiments approximately 185° to 195° C. The pressure in the reaction chamber during modified ORGANOSOLV™ processing is generally from about 19-30 barg. For any given solvent composition, desired temperatures during modified ORGANOSOLV™ processing produce pressures that substantially prevent the solvent from boiling.
[0022] According to some embodiments, the solvent extraction is carried out on a substantially continuous processing basis, in a reaction vessel that provides co-current or countercurrent flow of solvent and biomass feedstock. The modified ORGANOSOLV™ process, as described herein, particularly employing continuous processing, reduces the re-condensation and re-deposition of lignin often seen in batch reactors by allowing removal of solvent at temperatures well above the normal boiling point of the solvent. Alternatively, the solvent extraction may be carried out as a batch reaction or, according to some embodiments, as a batch reaction repeated two or more times. The solids:liquid ratio during solvent extraction is preferably at least 1:1 and, in some embodiments may be at least 1:2, in some embodiments at least 1:3; and in yet additional embodiments up to about 1:4.
[0023] Residence time of the plant material in the reaction chamber, or solvent extraction digester, is generally at least about 20 minutes and may be from about 20 to 80 minutes. In alternative embodiments, the residence time may be from about 30 to 70 minutes or, in yet other embodiments, from about 40 to 60 minutes. A residence time in the solvent extraction digester sufficient to produce a “black liquor” solution containing lignin soluble in the aqueous ethanol solvent is suitable. The modified ORGANOSOLV™ extraction is preferably carried out substantially in the absence of an acid or alkaline catalyst. For example, the reaction mixture may contain less than 1% of an introduced acid or alkaline catalyst and, according to some embodiments, the reaction mixture contains no introduced acid or alkaline catalyst.
[0024] In certain embodiments, the modified ORGANOSOLV™ extraction is carried out at a pH (measured with a glass electrode at room temperature) in the range of from about 3 to 9.5. In yet other embodiments, the modified ORGANOSOLV™ extraction is carried out at a pH of more than about 4 and less than about 8 and, in still other embodiments, the modified ORGANOSOLV™ extraction is carried out at a pH of more than about 5 and less than about 7.
[0025] In another embodiment, a hot water treatment may be used alone, or in combination with (e.g., following) a solvent extraction process, to extract additional lignin from plant material, and/or from a plant pulp material recovered following solvent extraction. Suitable hot water treatments may involve contacting the plant or pulp material with an aqueous solution (e.g., water) at an elevated temperature (e.g. from about 130° C. and 220° C.) and at an elevated a pressure (e.g. from about 2-25 barg) for a retention time sufficient to remove hemicellulose sugars from the plant and/or plant pulp material, and then separating the aqueous solution from the treated solids and harvesting isolated lignin from the aqueous solution to produce a high grade lignin product.
[0026] Water-soluble sugars such as xylose, as well as acetic acid and/or furfural may also be recovered from the aqueous hot water treatment solution. The resulting plant pulp material may be further processed to hydrolyze cellulose present in the plant material to glucose. This further processing may, for example, involve saccarification and/or fermentation. In one embodiment, the resulting plant pulp material is contacted with: (i) an aqueous solution comprising cellulase, β-glucosidase and temperature-tolerant yeast, (ii) yeast growth media, and (iii) buffer to hydrolyze cellulose present in the plant pulp material to glucose, which in turn may be fermented to produce ethanol.
[0027] Lignin extracted from plant materials in a solvent extraction process as described above may be isolated and harvested, for example, by depressurizing the black liquor removed from the solvent extraction process, and removing the solvent (using, e.g., flash cooling, steam stripping, and similar processes), followed by precipitation of lignin. Precipitation of isolated lignin may be accomplished, for example, by dilution of the solvent mixture (generally from about 2 to 10 times, by volume) with an aqueous solution such as water and, optionally, by lowering the pH to less than about 3 by addition of acid. Addition of acid is generally not required, or the requirements are minimal, for harvesting lignin extracted from Salix and other hardwoods, but acid addition may be desirable for precipitation of lignin derived from other plant materials. In general, the use of hydrochloric acid is preferred to the use of other mineral acids if acid addition is desirable for precipitating lignin. This may desirably reduce the formation of condensation reaction products during processing. The isolated lignin precipitate may be harvested by filtration or centrifugation or settling, and dried.
[0028] Alternatively, lignin extracted from plant materials in a solvent extraction and/or a hot water process and solubilized in an aqueous solvent solution may be isolated, for example, using a dissolved-gas-flotation process (e.g., “DAF-like process”). The solubilized lignin and solvent solution (e.g., black liquor) is generally cooled and may optionally be filtered, and is then mixed with a gasified solution. The gasified solution is generally an aqueous solution such as water. The volume of gasified solution is preferably from about 2 to 10 times that of the lignin solvent solution. In one embodiment, black liquor may be introduced into a mixing device that provides conditions of generally high fluid shear to provide rapid and substantially complete mixing of gasified solution with the black liquor. The gasified solution may be supersaturated, for example, with a gas such as CO 2 , nitrogen, air, or a gas mixture. During mixing with the aqueous solution, the hydrophobic lignin precipitates and is immiscible in the aqueous solution. Gas bubbles attach to the precipitated lignin and transport the precipitated lignin to the surface of the vessel, where it may be harvested using a DAF clarifier or by physical removal of the precipitated, buoyant lignin particulates. This lignin separation technique is an effective and gentle processing technique for recovering high grade lignin isolated from plant material using solvent extraction techniques, and may additionally be used to isolate lignin extracted from plant material using other techniques for extracting lignin from plant materials. Lignin separation and harvesting using a dissolved-gas-flotation technique may be carried out on either a batch basis or a continuous or semi-continuous processing basis.
[0029] In another aspect, methods for recovering lignin from an aqueous suspension of lignin are provided. These methods may be useful in recovering lignin which has been precipitated from an aqueous ethanol solution by dilution, and the precipitate subsequently washed in water. Such methods include adding at least one component selected from the group consisting of: ethanol at a concentration of less than 40% v/v; ammonium salts other than ammonium bicarbonate; and detergents other than Tween™ 80 or sodium dodecyl sulphate. This causes the lignin to flocculate, whereby the lignin may be readily harvested from the suspension. In certain embodiments, ethanol is added at a concentration of between about 2% and 38% v/v, for example at a concentration of about 9% to about 29% v/v. The ammonium salt may, for example, be ammonium sulfate or ammonium chloride, and may be added at a concentration greater than 4 mM. Detergents that may be effectively employed in such methods include, but are not limited to, Triton™ X-100, Triton™ X-114 and Nonidet™ P40. In one embodiment the detergent is added at a concentration greater than 4 ppm. This method can be useful for desalting any type of lignin preparation, to separate lignin from unreacted product and/or to selectively recover lignin sub-fractions for specific applications.
[0030] Because of its superior quality and its distinctive properties and structure, the high grade isolated lignin disclosed herein may be preferred over lignin isolated using different methodologies in the formulation of lignin-containing materials. The high grade lignin disclosed herein may be introduced, for example, in a variety of carbon based materials to provide products having an equivalent or higher quality than those produced using fossil fuel-derived raw materials or feedstocks, or other plant-derived lignins. Because of its superior blending capacity, the high grade isolated lignin disclosed herein may also be introduced in generally high proportions in a variety of resins used in the formulation of adhesives, films, plastics, paints, coatings and foams. The disclosed isolated lignin is also suitably reactive with other materials containing cross-linkable functional groups and amenable to chemical modification, resulting in increased reactivity. In general, shorter reaction times are required, and lower amounts of reactant are used and lost in processing isolated lignin of the present invention, resulting in cost reduction and more efficient chemical lignin modification. Also, as a consequence of its substantial homogeneity and purity, the thermal degradation of the isolated lignin disclosed herein generally yields a less complex mixture of products that may be upgraded or purified in further processing.
[0031] Isolated lignin of the present invention, derived from renewable and sustainable plant sources may be used, in many applications, as a substitute for petrochemicals and fossil fuel derived materials that are currently used as raw materials in the plastics and chemical industries. As a consequence of its distinctive structural properties, substantial homogeneity and composition, isolated lignin disclosed herein may be used, for example, as a renewable and sustainable phenol biopolymer for synthesizing phenolic and epoxy resins, providing a substitute feedstock for the petrochemical-based phenol polymers that are currently used as feedstocks for synthesizing phenolic and epoxy resins.
[0032] Phenolic resins encompass a variety of products formed by the reaction of phenol and aldehydes. Phenolic resin based adhesive acts as a matrix for binding together various substrates, including wood, paper, fibers (e.g., fiberglass), and particles (e.g., wood flour, foundry sand, etc.), to form cross-linked composites. Other aromatic hydrocarbons used in these reactions include cresols, xylenols, and substituted phenols. The aldehydes are usually formaldehyde, paraformaldehyde and/or furfural. Various other additives and reinforcing compositions may also be used to provide resins and end-use materials having a variety of properties.
[0033] Epoxy resins, like phenolic resins, are liquid or solid resins which cure to form hard, insoluble, chemical resistant plastics. Resins derived from bisphenol-A are among the most widely used epoxy resins. Bisphenol A is produced by liquid-phase condensation of phenol with acetone (a by-product of phenol synthesis). The chemistry of epoxy resin and the range of commercially available variations allow cured polymers to be produced with a very broad range of properties. The exceptional adhesion performance of epoxy resin is due to the presence of polar hydroxyl and ether groups in the backbone structure of the resin. Epoxy resins are also known for their chemical and heat resistance properties. There are many ways of modifying epoxy resins: for example, addition of fillers, flexibilizers, viscosity reducers, colorants, thickeners, accelerators, adhesion promoters. As a result many formulations tailored to the requirement of the end user can be achieved. These modifications are made to reduce costs, to improve performance, and to improve processing convenience. The applications for epoxy based materials are extensive and include coatings, adhesives and composite materials. Tremendous growth in the electronics market has markedly increased the demand for the epoxy resins for the manufacture of printed circuit boards and epoxy moulding compounds for semiconductor encapsulation.
[0034] Lignin has been used as a phenol replacement in thermoset resin. Olivares, (1988), Wood Science and Technology, 22:15; Sarkar (2000), Journal of Adhesion Science and Technology, 14:1179; çetin (2002) Int. J. Adhesion and Adhesives 22:477; çetin (2003) Turk. J. Agric. For. 27:183-189; Sellers, (2004) For. Prod. J. 54:45. Phenolic adhesive (liquid or powder) has been formulated with lignin from various sources to replace from 20-80% of the phenol component, or as filler in the resin itself. The inclusion of lignin in resin formulations generally reduces the curing time and the cost of production of the resin, and yields a product with improved strength, water resistance, thermal stability and durability.
[0035] The use of lignin to partially displace phenol in adhesive manufacture has also been successfully applied to the manufacture of friction products including automotive brake pads and mouldings. The preference for lignin, in the case of phenol-formaldehyde based adhesives, is also based on documented co-displacement of formaldehyde in addition to the reduction in emissions of toxic volatile organic compounds. Bisphenol A based epoxy adhesive has been modified by polyblending with lignin.
[0036] Epoxy resin formulations containing at least 50% lignin exhibit acceptable physical and electrical properties for a wide range of applications. IBM developed epoxy/lignin resin formulation for the fabrication of printed wiring boards to reduce the environmental concerns with the fabrication, assembly, and disposal of this product. The laminates formed from lignin based resins are processed in a similar fashion to current laminates, minimizing the financial considerations of converting to this resin system. In one study, a comparison of the lignin-based resin and current resins through a life-cycle assessment indicated a 40% reduction in energy consumption for the lignochemical based resin. Isolated lignin of the present invention may be used in any and all of these applications.
[0037] The disclosed lignin may also provide a polyol backbone for reaction to produce compositions such as polyurethane resins. In this application, the disclosed lignin may replace petrochemical-based polyol feedstocks currently used in the production of polyurethane resins. Polyols are compounds with multiple hydroxyl functional groups available for organic reactions. More than 75% of all the polyols produced globally are used in the manufacturing of polyurethane resin. The polyols provide the backbone structure of the PU resin and may be polyether, polyester, polyolefin or vegetable oil based; the first two being the most widely used. Polyether-based polyols are generally obtained from the base-catalyzed polymerization of cyclic ethers (propylene, ethylene and butylene oxides) to a hydroxyl or amine-containing initiator. Polyester polyols are generally produced by condensation of a diol (ethylene glycol, propylene glycol) and a dicarboxylic acid. Aromatic polyester polyols are generally derived from phthalic acid. A major cost in the production of polyols is attributed to the costs of propylene oxide. Propylene oxide (PO) is a liquid commodity chemical (derived from butane/isobutane, propylene, methanol and oxygen), used in the production of derivative products, including polyether polyols, propylene glycol, propylene glycol ethers and various other products.
[0038] Polyether polyols are used for the formulation of polyurethane resin for manufacture of softer, elastic and more flexible products (spandex elastomeric fibers and soft rubber parts, as well as soft foam) used in automobile and recreational vehicle seats, carpet underlay, furniture upholstering, bedding, and packaging. Polyfunctional polyester polyols are largely used in the formulation of polyurethane resin used for the manufacture of more rigid products such as low density foams of high grade thermal insulation, or structural construction products. Polyurethane rigid foam has grown in use because of its combination of low heat transfer and cost effectiveness. Applications for polyester flexible urethane foam include gaskets, air filters, sound-absorbing elements, and clothing inter liners (laminated to a textile material). Generally, polyether-based foams have a greater hydrolysis resistance, are easier to process, and cost less. Polyester-based foams have a more uniform structure with higher mechanical properties and better oil and oxidative degradation resistance. Both types can be sprayed, moulded, foamed in place, or furnished in sheets cut from slab.
[0039] Aromatic polyester polyol has become the polyol of choice for the formulation of rigid polyurethane foam. The use of aromatic polyester polyol in conjunction with polyurethane chemistry has counteracted the adverse effects of the flammability characteristic resulting from a change to non-CFC blowing agents. Polyester polyols provide superior mechanical properties, such as tensile strength, abrasion, and wear resistance, as well as solvent and oil resistance, to the polyurethanes in which they are used. With the phase-out of hydrochlorofluorocarbon blowing agents, polyester polyol producers are challenged to provide products to the polyurethane industry suitable for use with next generation blowing agents. New products must produce foams with an excellent balance of properties, and concurrently maintain cost-effectiveness and environmentally friendliness.
[0040] Lignins, like polyols, have multiple aromatic and aliphatic hydroxyl functional groups making them reactive towards MDI or TDI (diphenylmethane diisocyanate (MDI) or toluene diisocyanate (TDI)). With its aromatic ring, lignin can act as a flame retardant (like phthalic acid derived aromatic polyester polyol) in polyurethane applications. Lignin has been used to replace the polyol component of polyurethane resins, prepared by the polyaddition reaction of a difunctional isocyanate molecule to the hydroxyl groups of the polyol forming a series of block copolymers with alternating hard and soft phases. A whole spectrum of PU can be prepared from a wide range of polyols with different functionality and molecular weights and just a few types of di-isocyanate. One of the most desirable attributes of polyurethanes is their ability to be turned into foam by the addition of a blowing agent. Use of lignin in the rigid foam industry would improve both hydrolytic and UV resistance. Lignin of the present invention may be efficiently introduced in the formulation, for example, of polyurethane coatings, adhesives and foams.
[0041] The isolated lignin disclosed herein may be used in any and all of these applications, for example, as a filler or to replace specific components in the formulation of plastics resins (such as phenols, epoxies, polyurethanes, polyvinyls, polyethylenes, polypropylenes, polystyrenes, polyimides, polycarbonates, formaldehydes, acrylics, acrylonitrile-butadiene-styrenes and alkyds-based), used in the manufacturing of thermoset or thermoplastic material such as adhesives, binders, coatings, films, foams, rubbers, elastomers, carbon fibers and composites.
[0042] Polyvinyl chloride (PVC) is an extremely versatile material and can be converted into rigid products, and flexible articles when compounded with plasticizers. Unmodified PVC resin has very little utility due to poor physical properties and processability. PVC is almost always converted into a compound by the incorporation of additives such as plasticizers, heat stabilizers, light stabilizers, lubricants, processing aids, impact modifiers, fillers, flame retardants/smoke suppressors, and, optionally, pigments. Rigid PVC applications include pipes and fittings largely for water service; profiles for windows, doors, and siding; film and sheet for packaging and construction; and blow moulded containers for household and health and beauty products. Flexible PVC with high plasticizers loading is used in a variety of applications including film and sheet for packaging, coated fabrics for upholstery and wall coverings, floor coverings for institutional and home use (bathrooms and kitchens), tubing for medical and food/drink uses, and wire and cable insulation.
[0043] The manufacture of PVC is generally expensive, and raw material costs are generally high. In addition, there is considerable PVC-related toxicity, including toxic and potentially endocrine-disrupting effects of various additives used in PVC compounds, use of chlorine with potential for atmospheric ozone depletion, formation of dioxin from incineration of PVC and possible leaching of hazardous materials following disposal of PVC. Partial replacement of PVC (20 parts) with different lignins is already feasible for some formulations that can be successfully used as matrices for a high level of calcium carbonate filler in flooring products. The introduction of the isolated lignin of the present invention in these types of materials will not only reduce the cost and environmental imprint of plastics made from these materials but will also produce plastics with a better resistance to UV, thermal, hydrolytic, oxidative and biological destabilization.
[0044] Carbon fibers are generally used as long, thin strands of material about 0.005-0.010 mm in diameter, and composed mostly of carbon atoms. Several thousand carbon fibers are twisted together to form a yarn, which may be used itself, or woven into a fabric. The yarn or fabric may be combined with epoxy, for example, and wound or moulded into shapes to form various composite materials.
[0045] Carbon fibers are generally made using a partly chemical and partly mechanical process. Acrylonitrile plastic is mixed with another plastic (such as methyl acrylate) and reacted with a catalyst. The precursor blend is then extruded into long fibers, and stretched to a desired diameter. The fibers must then be stabilized (via heating in air at low temperatures 200-300° C.), before carbonizing them (via heating in the absence of oxygen at high temperatures (e.g. 1000-3000° C.). The fibers undergo a surface oxidation to allow them to react more effectively with chemical and mechanical bonding. The final treatment is to coat the fibers (sizing) which protects them from damage in winding and weaving. The coated fibers are wound onto bobbins, and are referred to as a “tow” that can be twisted into yarns of various sizes. Carbon fibers are generally supplied by producers as a continuous fiber or as a chopped fiber. Carbon fibers may be combined with thermoset and thermoplastic resin systems and are mainly applied to reinforce polymers, much like glass fibers have been used for decades in fiber glass. They have many uses in specialty type industries like the aerospace industry, and automobile industry.
[0046] The disclosed lignin may be used as a carbon skeleton suitable for manufacturing carbon fibers and carbon fiber compositions, and may replace synthetic polymers such as polyacrylonitrile (PAN) in the production of carbon fibers and carbon fiber compositions.
[0047] The disclosed lignin moreover provides a superior feedstock that may be broken down to provide aromatic or repeated units that are useful as fine chemicals. In addition, the disclosed lignin may be used as a superior quality feedstock for thermodegradation to bio-oil, synthesis gas, char, or fine chemicals via hydrothermal treatment, gasification or pyrolysis. The high grade isolated lignin disclosed herein may also be employed as a plasticizer, as a UV stabilizer, as described, for example, in U.S. Pat. No. 5,939,089, or as a water repellent.
[0048] In addition, because of its unique properties (molecular weight profile, chemical and molecular structures), the lignin disclosed herein can be employed in various applications to provide antioxidant, immunopotentiation, anti-mutagenic, anti-viral and/or anti-bacterial activity, and to improve the general health of animals or humans.
[0049] Because the disclosed isolated lignin has a generally high reactivity and a generally low contaminant composition, higher ratios of the disclosed isolated lignin can be used as a feedstock for making many products requiring polymer feedstocks without deleteriously affecting the properties of the final product. As a result, the high grade isolated lignin disclosed herein may be employed in a wide range of products, leading to a reduction in the amount of fossil fuel carbon, toxic substances and non-biodegradable materials required to manufacture these products and thereby contributing to the efficient and sustainable use of resources. In addition, the high grade isolated lignin disclosed herein is a relatively inexpensive feedstock and drastically reduces the cost of materials such as carbon composites, epoxy-type resins, polyurethane and other products that otherwise require high cost, petrochemical-derived feedstocks.
[0050] Processing of biomaterials using a modified ORGANOSOLV™ process that employs a low boiling solvent, preferably comprising ethanol, and substantially in the absence of an acid catalyst, also increases the recovery and integrity of xylan polymers. In a hot water treatment, either alone, or following a solvent extraction process, the xylan polymers are hydrolyzed, yielding their monomer units in the water hydrolysate. The xylose rich water hydrolysate provides another valuable product stream from which crystalline xylose, furfural and/or xylitol may be derived. The xylose rich water stream may also be used as a fermentation substrate for the production of ethanol, xylitol and other valuable fermentation products, providing additional valuable polymer feedstocks for use directly or for further processing.
[0051] Xylose may thus also be produced using the processing methodology disclosed herein. Specifically, large quantities of the five carbon sugar xylose are released as a yellow liquor in a hot water washing of pulp, independently of or following lignin removal by solvent extraction. Currently, xylose-rich yellow liquors are generally produced by acid hydrolysis of birch wood, bagasse, rice husks, corn and wheat straw. Xylose, furfural, xylitol and other products of an extraction process (e.g., a hot water extraction process as disclosed herein), using the plant material feedstocks disclosed, herein are also contemplated as products of the present invention.
[0052] Xylose is used for the production of furfural used in the formulation of industrial solvents. Xylose of the present invention may be used for the production of furfural, as well as directly, or in xylose-derived products, as a food or beverage additive in human, animal and other organism feeds. In addition, xylose of the present invention may be used as a feedstock for conversion (e.g., via hydrogenation) to xylitol, a sugar alcohol used as non-carcinogenic, low calorie sweetening compound. Xylose and concentrated xylose syrups and crystalline cellulose of the present invention are suitable for use as ingredients by food industries (human and animal, for example). The xylose-rich yellow liquor of the present invention may also be used without further processing as a fermentation substrate for the biochemical production of ethanol. In various aspects, products of the present invention include: the xylose-rich yellow liquor derived using the methods disclosed herein; xylose isolated from the yellow liquor; and yellow liquor and isolated xylose derived from hardwoods, including copiccable hardwoods such as Salix , as well as from the other plant material raw materials disclosed herein.
[0053] Xylitol is used as a low calorie food sweetener. It is as sweet as sucrose, provides a cooling effect, has no after-taste, and is safe for diabetics as it is metabolized independently of insulin. It has 40% less calories than sugar and is the only sweetener to show both passive and active anti-caries effects. Xylitol is used in a wide range of applications in the food industry as a sugar substitute (e.g. in confectionery, gum and soda) and in the pharmaceutical and personal care industries (e.g. in oral hygiene products and cosmetic products).
[0054] Xylitol is produced commercially by hydrogenation of xylose obtained from birch wood sulphite pulping liquor and other xylan-rich substrates. The production process involves the extraction and purification of xylose from the pulping liquor, a chemical hydrogenation reaction, and the recovery of xylitol by chromatographic methods. The chemical based conversion of xylans to xylitol is approximately 50-60% efficient. Alternative technology based on microbial reduction of xylose from xylan rich hydrolysate is considered to be ‘cleaner’ and generally requires less energy than the chemical conversion. The present invention contemplates xylitol produced by hydrogenation of xylose isolated from hardwoods, including coppicable shrubs such as Salix . In various aspects, products of the present invention include: xylitol produced using the xylose-rich yellow liquor derived using the methods disclosed herein; xylitol produced using xylose isolated from the yellow liquor; and xylitol produced using isolated xylose derived from hardwoods, including coppicable hardwoods such as Salix , as well as from the other plant material raw materials disclosed herein.
[0055] Furfural is an aromatic aldehyde obtained by catalytic dehydration of a xylose concentrate solution. Furfural is an intermediate commodity chemical used in synthesizing a range of specialized chemical products, starting mainly with furfural alcohol (FFA), which also has many derivatives. Furfural is used in the production of resin (phenol, acetone, or urea based) used as a binding agent in foundry technologies or in the manufacture of composite for the aeronautic and automotive industries. Furfural is also used as a selective solvent in petroleum production of lubricants. There are many other uses (e.g. adhesive, flavoring and as a precursor for many specialty chemicals), but resins account for over 70 percent of the market. Furfural is highly regarded for its thermosetting properties, physical strength and corrosion resistance. Furfural is important in terms of its presence, as a carbohydrate, in a chemical industry dominated by hydrocarbons.
[0056] In addition to providing a high quality xylose suitable for conversion to furfural, modified ORGANOSOLV™ treatment followed by hot water extraction provides a furfural-rich yellow liquor. In various aspects, products of the present invention include: furfural produced using the furfural-rich yellow liquor derived using the methods disclosed herein; and furfural derived from hardwoods, including coppicable hardwoods such as Salix , as well as from the other plant material raw materials disclosed herein.
[0057] In yet other aspects, products of the present invention include celluloses, sugars (e.b., glucose), hemicelluloses, and downstream products produced using such products, including ethanol and other fermentation products derived from hardwoods, including coppicable hardwoods such as Salix , as well as from the other plant material raw materials disclosed herein.
[0058] These and additional features of the present invention and the manner of obtaining them will become apparent, and the invention will be best understood, by reference to the following more detailed description and the accompanying drawings.
BRIEF DESCRIPTION OF THE FIGURES
[0059] FIG. 1 is a schematic of the first stage (ethanol extraction) of an integrated process for the production of biofuel and lignin from wood chips.
[0060] FIG. 2 is a schematic of the second stage (hot water treatment) of an integrated process for the production of biofuel and lignin from wood chips.
[0061] FIG. 3 is a schematic of the third stage (simultaneous saccharification and fermentation) of an integrated process for the production of biofuel and lignin from wood chips.
[0062] FIG. 4 is a schematic of the fourth stage (product separation/purification) of an integrated process for the production of biofuel and lignin from wood chips.
[0063] FIG. 5 is the 2D 13 C- 1 H correlation (HSQC) spectra of lignin side chain regions, acquired during NMR analysis of an isolated lignin sample described herein.
[0064] FIG. 6 is the 2D 13 C- 1 H correlation (HSQC) spectra of side chain region, acquired during NMR analysis of a Kraft lignin (Sigma-Aldrich #370959) sample.
[0065] FIG. 7 shows the volume integration of the 2D 13 C- 1 H correlation (HSQC) spectra of side aromatic units, acquired during NMR analysis of an isolated lignin sample described herein.
[0066] FIG. 8 illustrates gel filtration elution profiles showing the molecular weight distribution of an isolated lignin sample of the present invention in FIG. 8A (BJL5), a commercial Kraft lignin (Sigma-Aldrich #370959) sample in FIG. 8B , and a commercial ORGANOSOLV lignin (Sigma-Aldrich, #37101-7) sample in FIG. 8C .
DETAILED DESCRIPTION
[0067] As discussed above, the present invention provides high grade isolated lignin polymers obtained from processing of plant materials, such as lignocellulosic plant materials. Ligocellulosic plant materials are harvested, air-dried and stockpiled. Reduction of the particle size of the harvested plant material may be desired prior to processing, and this can be achieved using a chipper or similar device to mechanically reduce the size of the plant material feedstock. Suitable size reduction techniques are well known in the art and one of ordinary skill in the art may readily determine appropriate particle sizes and size distributions for various types of feedstocks used in the present invention.
[0068] In one solvent extraction methodology, the first stage of the process disclosed herein is a modified ORGANOSOLV™, or aqueous ethanol extraction (illustrated schematically in FIG. 1 ). In one embodiment, this involves continuously contacting a lignocellulosic plant material with a counter-current flow of an aqueous solution comprising up to 80% ethanol, undertaken at a temperature of approximately 170° C. to 210° C. and a pressure of 19-30 barg. In one embodiment, the digester is a screw contactor operating with wood chips being fed and discharged via cup and cone pressure plugs or feed screws. Solvent passes against the flow of solids so that plant material exiting the digester is exposed to fresh (solute free) ethanol solution, while chips entering the digester, which have the highest extractable content, are exposed to the most solute laden solvent solution.
[0069] Solvent entering the digester may be pressure pumped to maintain the operating pressure therein and to provide the hydraulic drive to pass against the flow of chips. Solvent from within the digester is re-circulated through external heaters, for example steam heaters, on a continuous basis to bring the wood chips up to the operating temperature quickly and to maintain the temperature. Operating conditions (such as time, temperature profile, pressure and solids/liquid ratio) within the digester may be optimized to provide maximum removal of water insoluble lignin from the plant material. As the plant material exits the digester and is exposed to lower pressures, a portion of the solvent content therein evaporates, resulting in cooling of the treated plant material. In alternative embodiments, the plant material may be displaced in the digester using gravity in a downward gradient. Solvent entering the digester may be pumped against the flow of solids. Multiple solvent extraction stages may be provided. Lignin is solubilized in the aqueous ethanol solvent (“black liquor”) and may be isolated from the “black liquor” produced during solvent extraction.
[0070] Plant material, or pulp, discharged from a solvent extraction stage of the process still contains some ethanol, which is preferably removed prior to a subsequent water extraction step. Solvent removal may be achieved by means of a steam stripping operation. The vapors recovered from both this operation and from other solvent recovery techniques, may be collected and re-used directly with the fresh solvent stream. In this way the latent heat content of the vapors is recovered.
[0071] The de-solventized plant pulp material may optionally be processed in a second stage of extraction (illustrated schematically in FIG. 2 ), which may be undertaken in comparable equipment and in a comparable fashion to the ethanol extraction described above, with the difference being that high pressure hot water (preferably at a pressure of approximately 2 to 25 barg and a temperature of approximately 130° C. to 220° C.) is utilized to solubilize the hemicellulose sugars in the plant pulp material. As the solids exit the hot water digester and the pressure is reduced, flash evaporation of steam occurs. This may be recovered for direct re-use with the fresh hot water entering as fresh extraction solvent at the solids discharge end of the digester. The treated plant pulp is also cooled as a result of this flash evaporation.
[0072] The non soluble constituents of the initial plant material that remain in the pulp after two stages of extraction (solvent and hot water) are primarily cellulose and other sugars present in the form of a hydrolyzable pulp. This material may be hydrolyzed to produce glucose. In one hydrolysis procedure, the hydrolyzable pulp is transferred to one of a series of batch SSF (simultaneous saccharification and fermentation) vessels, together with temperature-tolerant yeast, yeast growth media, cellulase, β-glucosidase, buffer and water to dilute the solids to the required solid/liquid ratio (illustrated schematically in FIG. 3 ). In these vessels, the cellulose is hydrolyzed to produce glucose, which is in turn fermented to produce ethanol. Low levels of ethanol are maintained in the fermentor by continuous removal of the produced ethanol to avoid fermentation inhibition. The process is optimized for maximum cellulose hydrolysis and fermentation to ethanol. The vessel contents at the end of the batch fermentation will be discharged via a filter and the retained solids will be disposed of, or recovered to be further processed to yield additional products. The filtrate, consisting primarily of ethanol and water, may be concentrated to produce hydrous and/or anhydrous ethanol as desired, using methods well known to those of skill in the art. A portion of the hydrous ethanol product may be re-utilized in the first, ethanol extraction stage.
[0073] Products, such as high grade lignin, are separated and purified as illustrated schematically in FIG. 4 . In one embodiment, the black liquor (ethanol/water/lignin solution) exiting the solvent extraction digester in the first stage may be depressurized before passing to a flash cooling vessel in which the solvent is evaporated. Further ethanol may then be steam-stripped from the liquor prior to transfer to one of a series of batch vessels, in which precipitation of lignin from the liquor is promoted through dilution (generally from about 2 to 10 times, by volume) with water. The pH of the diluted black liquor may be reduced by acid addition to increase the lignin precipitation rate, if desired. After settling, the lignin sludge may be dewatered by filtration and/or centrifugation and dried to produce an isolated lignin product.
[0074] Alternatively, the lignin solubilized in the black liquor may be recovered using a dissolved gas flotation (DAF-like) based process as described below. Because of its low cost, gentle recovery conditions and rapid recovery, the dissolved gas flotation method described herein is preferred for many lignin isolation and harvesting processes compared to conventional methods like settling and centrifuging and may be used to harvest lignin extracted from plant materials using a variety of extraction techniques. In this embodiment, after flash cooling, the black liquor may optionally be filtered and the solubilized lignin in an aqueous solvent solution is then mixed with a gasified aqueous solution (e.g., water). The gasified solution contains a high concentration of a gas such as air, nitrogen, CO 2 , mixtures thereof, and the like. The pressure and gas flow rates may be adjusted to provide desirable gas concentrations, properties, etc. in the lignin recovery vessel.
[0075] Gasified aqueous solutions may be prepared, for example, by storing water in a pressure vessel under nitrogen, carbon dioxide or any other suitable gas at a pressure of at least 2 barg. The water level in the pressure vessel is regulated by the use of a float valve or similar device. Compressed air, nitrogen or carbon dioxide (such as CO 2 recovered from the fermentation process) may be admitted at the base of the tank, and the incoming gas may be passed through a sparger to increase the dissolution rate of the gas in the aqueous solution. The gasified solution is withdrawn from the pressure vessel through a metering valve which regulates its flow rate. As the gasified solution leaves the tank and is mixed with the black liquor, the decrease in pressure leads to the generation of many small gas bubbles (“microbubbles”) which attach to the hydrophobic lignin precipitate as it forms, and cause it to float to the surface.
[0076] In one embodiment, (optionally filtered) black liquor comprising lignin solubilized in an aqueous solvent solution is pumped (using, for example, a metering pump) into a mixing device, such as a venturi mixer or a similar device. The mixing device preferably creates conditions of high fluid shear to provide rapid and complete mixing of the gasified water with the black liquor, and is preferably constructed from materials that minimize the amount of lignin adhering to the surfaces of the device. When the solubilized lignin is diluted in the aqueous solution, the hydrophobic lignin precipitates and forms immiscible particulates in the aqueous solution. Microbubbles of gas attach themselves to the immiscible lignin particles and transport them to the surface of the mixed solution. The floating lignin may then be separated by mechanical means. In one embodiment, the floating lignin particulates are pushed toward a conveyer belt by means of a paddle, for example. The conveyer belt may be constructed from a porous material, allowing partial dewatering of the lignin as it is harvested. The speed and length of the conveyer belt may be adjusted to provide optimum harvesting efficiency and lignin drying. It will be apparent to one of ordinary skill in the art that different types of lignin harvesting processes may also be used. After lignin removal, the ethanol may be separated from the water and recycled, while the aqueous fraction may be combined with a hot water stream for use in further processing, such as xylose and water soluble product recovery.
[0077] The present invention further provides methods for recovering lignin from an aqueous suspension of lignin. In one embodiment, the lignin may be recovered from water washes by a process in which ammonium salts (e.g., 10 mM ammonium chloride or ammonium sulfate, but not ammonium bicarbonate) or low concentration detergents (e.g., 50 parts per million of Triton™ X-100 ((C 14 H 22 O(C 2 H 4 O)n) or Nonidet™ P40 (nonylphenyl-polyethylene glycol), but not Tween™ 80 (polyoxyethylene (20) sorbitan monooleate) or sodium dodecyl sulphate, are added to the solution. This causes the lignin suspended in the water washes to flocculate, facilitating harvesting of the washed lignin. The effects of detergents and ammonium salts are additive. The use of ammonium chloride to aid in the harvesting of washed lignin precipitates may be particularly advantageous, as ammonium chloride is volatile, and excess ammonium chloride can thus be easily removed from the harvested lignin during the drying process. Ethanol may also be used to recover the washed lignin. At low concentrations (for example less than 35% v/v), ethanol induces the precipitation of lignin from a water suspension. The use of ethanol in this process is particularly advantageous because it is volatile and can thus be easily removed from the harvested lignin during the drying process.
[0078] Raw lignin material isolated from Salix viminalis or Salix schwerinii ‘Kinuyanagi’ using the process described above employing 70% aqueous ethanol at 185° C. for 60 minutes, and harvested by precipitation and centrifugation from the black liquor or using the dissolved gas flotation described above, was shown to have a high degree of similarity to natural lignin, to retain a high degree of reactivity and to be relatively pure, with a minimal amount of carbohydrate contamination. In preferred embodiments, isolated lignin preparations of the present invention comprise less than about 1.0% sugars; in some embodiments less than about 0.2% sugars and, in yet additional embodiments, less than about 0.5% sugars. In some embodiments, isolated lignin compositions of the present invention have a carbohydrate composition of less than about 0.2 g per liter supernatant detectable by HPLC using an ion exclusion column following hydrolysis of the lignin preparation with concentrated sulfuric acid. In addition, isolated lignin preparations of the present invention are substantially free from salts and particulate components.
[0079] Isolated lignin having a relatively high ratio of syringyl (S) units is preferred for many applications. Lignin extracted from Salix viminalis or Salix schwerinii ‘Kinuyanagi,’ or a mixture of both species, with 70% ethanol at 185° C. for a retention time of 60 minutes and harvested by precipitation and centrifugation was composed of approximately 80% syringyl (S) units (ratio S:G of 4:1) and had a low degree of chemical modification with a high proportion of β-aryl-ether and resinol subunits. In some embodiments, isolated lignin compositions of the present invention have a syringyl unit content of at least about 50%, in some embodiments, of at least about 60%, in yet other embodiments, of at least about 70%, and in still other embodiments of at least about 80%. Isolated lignin compositions of the present invention preferably have an S:G ratio of at least about 2:1; more preferably at least about 3:1 and, even more preferably for some applications, at least about 4:1.
[0080] Isolated lignin preparations made as described herein have an average molecular weight of about two to three times higher than comparative commercial Kraft and ORGANOSOLV lignin preparations, as demonstrated by the experimental evidence presented in Example 6, below. In some embodiments, isolated lignin compositions of the present invention have a weight average molecular mass (determined as described below) of at least about 4,000. In some embodiments, isolated lignin compositions disclosed herein have a weight average molecular mass (determined as described below) of at least about 4,500, and in yet other embodiments, the disclosed isolated lignin compositions have a weight average molecular mass (determined as described below) of at least about 5,000. In still other embodiments, isolated lignin compositions of the present invention have a weight average molecular mass (determined as described below) of at least about 5,500.
[0081] The isolated lignin preparations also have relatively high numbers of reactive hydroxyl groups that are important to provide reactivity with other chemicals or polymers, as well as high numbers of methoxyl groups of 30 to 40 per 100 units. In addition, the high grade isolated lignin disclosed herein is minimally modified and therefore has a reactivity that is closer to that of natural (“native”) lignin. Isolated lignin compositions of the present invention generally comprise detectable quantities of at least three side chains selected from the group consisting of phenylcoumaran, resinol, α-ethoxy-β-aryl-ether, and cinnamyl alcohol side chains. According to some embodiments, isolated lignin compositions of the present invention comprise detectable quantities of phenylcoumaran, resinol, α-ethoxy-β-aryl-ether, and cinnamyl alcohol side chains. The side chains present in isolated lignin preparations may be detected and measured using nuclear magnetic resonance spectroscopy analysis, for example.
[0082] High grade isolated lignin compositions of the present invention generally have a high ratio of β-aryl-ether subunits, generally at least about 40%, in some embodiments at least about 50%, and in yet other embodiments at least about 60%. High grade isolated lignin compositions of the present invention also have a generally high ratio of resinol subunits, generally at least about 6%, in some embodiments at least about 8%, and in yet other embodiments at least about 10%.
[0083] Because of its purity, homogeneity and unique reactivity, the isolated lignin preparations obtained as described herein can be used without further processing. However, if desired, residual volatile compounds may be removed by heat treatment, and non-volatile residual compounds may be removed, for example, using a water wash. In some embodiments, the isolated, raw lignin may be recovered from a water suspension using a selective flocculation method as described herein. In some embodiments, the isolated lignin may be harvested from the black liquor using a dissolved gas flotation technique as described herein.
[0084] The high grade isolated lignin disclosed herein is useful as a feedstock for a variety of downstream industrial processes and material manufacturing processes. In one embodiment, the high grade isolated lignin described herein can be melted or dry spun at a desired temperature and speed to produce carbon fibers using methods well known to those of skill in the art and including, but not limited to, those taught in U.S. Pat. Nos. 3,461,082 and 5,344,921. Because of its homogeneity, the disclosed lignin has the capacity to form regular, continuous filaments of carbon during extrusion. Also, because of the higher S unit ratio and lower condensation level, lignin prepared from Salix using the process described herein is stable during the thermostabilization of the carbon filament. If required, the spinning, extrusion and/or carbonization can be facilitated by blending the disclosed lignin with a plasticizer (for example polyvinyl alcohol (PVAL), polyethylene oxide (PEO) or polyester (PES)) or by condensation of lignin units following chemical modification of the lignin. The melting and extrusion of polycondensed high grade lignin or lignin polymer blend can also be useful for the production of composites and plastics.
[0085] Superior lignin-based polyurethane (PU) can be formulated by using the disclosed lignin either directly as a polyol precursor or blended with other polyol types (for example, polyethylene glycol (PEG), polyethyleneadipate (PEA) and/or polypropylene glycol (PPG)) to react with an isocyanate radical of polyisocyanates or isocyanate-terminated polyurethane prepolymers either in the presence or absence of a catalyst. The efficient functionalization of the disclosed lignin with diisocyanates also allows, upon reaction with polyols, the formulation of a high quality PU resin. In addition, the disclosed lignin can be functionalized with an epoxide for further reaction with an isocyanate or added as filler to a prepared PU resin. PU resin prepared using the disclosed high grade lignin can be used as a lower cost, high quality, adhesive and/or coating, or can be easily cast and cured for the formation of high quality films. When water or a foaming agent is added to the formulation of the lignin based PU, foams of various density levels can be produced.
[0086] Superior phenolic resins can also be formulated from the disclosed high grade lignin. Because of its higher reactivity compared to Kraft and sulfite lignins, the disclosed lignin will provide a superior replacement of phenol in many phenol based resins used in a wide variety of applications, ranging from adhesives to composites. The disclosed high grade lignin can be either directly blended with the phenol resin or incorporated into the resin at high ratios by condensation or derivatization with phenol or formaldehyde. The disclosed lignin may thus be used to produce a safe and biodegradable resin.
[0087] The natural properties of the high grade lignin disclosed herein can be modified by polymer blending. The lignin is able to form proper hydrogen bonding for miscible blend formation with plasticizing agents such as polyethylene oxide (PEO), polyethylene terephthalate (PET), polyvinyl pyrrolidone (PVP), polyvinyl chloride (PVC), polyvinyl acetate (PVA), polyethene-co-vinylacetate (EVA), polypropylene (PP), polyethylene (PE) and others, allowing further control of its thermal processability. This can be useful, for example, to facilitate the spinning, extrusion and/or casting of the lignin-based final product, or in the making of adhesives, paints coatings, plastics and the like. The stronger intermolecular interaction between polymers and the disclosed high grade lignin will create superior lignin-polymer blends with a positive impact on the derived composite.
[0088] The viscoelastic properties of lignin can also be altered and modified through chemical introduction of unsaturated carbonyl groups or nitrogen-containing compounds. Another advantage of the unique properties of the disclosed high grade lignin is the efficiency and lower cost of chemical conversion of its phenol, alkene or hydroxyl moieties into other functional groups. The disclosed lignin is more amenable to alkylation and dealkylation, oxyalkylation (for example, oxypropylation, for production of polyoxyalkylene polyethers), amination, carboxylation, acylation, halogenation, nitration, hydrogenolysis, methylolation, oxidation, reduction, polymerization, sulfomethylation, sulfonation, silylation, phosphorylation, nitroxide formation, grafting and composite formation. In general, such lignin modifications are inefficient and costly due to the presence of impurities, heterogeneity and high level of altered moieties in the conventional lignin preparations. These modifications can be performed more efficiently and at lower cost on the disclosed high grade lignin to produce useful polymeric materials.
[0089] Reactive epoxy functionality can be added at lower cost to the disclosed high grade lignin than with conventional lignin preparations. The disclosed lignin can be directly reacted with ethylene-unsaturated groups or hydroxypropyl groups to prepare a lignin-based epoxide with good solubility that may be used in co-polymerization reactions. The disclosed lignin is also a superior substrate for conversion into polyols by propoxylation (reaction with propylene oxide such as 2-methyloxirane) or ethoxylation (reaction with ethylenoxide such as oxirane) chain extension reaction. Epoxide-lignin resin may be cured to a hard infusible plastic and may also be reacted with fatty acids to produce resins for paints and inks or may be reacted with various amines to produce polyamines or polyamides for use as adhesives or plastics. Epoxidized high grade lignin may also be employed to reduce the need for polyol in PU resin and for displacement of phenol epoxy resin.
[0090] The following examples are offered by way of illustration and not by way of limitation.
Example 1
Recovery of Lignin from Salix
Preparation and Composition Analysis of Untreated Salix Biomass
[0091] Stems of Salix viminalis or Salix schwerinii ‘Kinuyanagi’ were chipped with a garden mulcher. The wood chips were dried at 40° C. for 24 hours and sieved by hand between two wire meshes of British test sieve with apertures of 2.8 and 4 mm. The composition of the sieved and unsieved Salix chips was assessed, with the results being shown in Table 1. The mass composition was assessed using laboratory analytical procedures (LAPs) developed by the National Renewable Energy Laboratory (NREL, Golden, Colo.). Values are expressed as gram of component per 100 g of dry untreated chips. Extractives were isolated using a Soxhlet extractor, dried and weighed. Lignin concentrations were determined after chemical hydrolysis of the Salix chips (4 hours with 72% sulfuric acid at 102° C.). Acid soluble lignin was measured by densitometry at 320 nm and the concentration of the non-acid soluble lignin was measured by weight minus ash. The percentage of glucan and xylan present in the samples were determined after chemical hydrolysis (4 hours with 72% sulfuric acid at 102° C.). Acid soluble sugar was measured by HPLC using the appropriate range of xylose and glucose standards. The composition of the untreated Salix material was determined and is shown below in Table 1.
[0000]
TABLE 1
Composition of untreated Salix biomass (*= Sieved material)
Ex-
trac-
tive
Lignin (%)
Sugar (%)
Salix variety
(%)
Soluble
Insoluble
Total
Glucan
Xylan
Salix viminalis *
16
2
31
33
23
9
Salix viminalis
8
3
24
27
34
8
Salix schwerinii
6
5
23
28
32
14
Salix schwerinii
4
5
22
27
33
12
Kinuyanagi
Salix schwerinii
4
3
25
28
33
9
Kinuyanagi
Salix schwerinii
2
4
28
32
35
9
Kinuyanagi +
Salix viminalis
Salix schwerinii
2
4
25
29
30
8
Kinuyanagi +
Salix viminalis
Average
6
4
25
29
31
10
Standard
5
1
3
3
4
2
Deviation
Pre-Treatment of Salix Biomass
[0092] A modified ORGANOSOLV™ treatment of Salix chips was tested in 100 ml experimental digester and 3 l packed-bed experimental digester that were able to process 6 g and 300 g of dry wood chips, respectively. The design of these two digesters is illustrated in and described with reference to FIG. 5 (100 ml digester) and FIG. 6 (3 l packed-bed digester) of U.S. Patent Publication US 2007/0259412 A1. A 40 l digester was also designed and tested for the recovery of natural lignin from Salix biomass at larger scale (shown in and described with reference to FIG. 7 of U.S. Patent Publication US 2007/0259412 A1). The 40 l digester processed 6 kg of dry biomass. Process conditions for solvent treatment of the Salix chips and subsequent hot water treatment of the plant pulp material recovered from the solvent treatment are also described in U.S. Patent Publication US 2007/0259412 A1. Lignin from the 100 ml and 3 l digesters was harvested by precipitation and centrifugation as described in U.S. Patent Publication US 2007/0259412 A1. Lignin from the 40 liter digester was harvested by precipitation and centrifugation and, in some instances, by dissolved air flotation techniques described herein.
[0093] At all scales (100 ml, 3 l packed-bed, and 40 l batch), sequential solvent extraction using an aqueous solution comprising 70% ethanol followed by hot water treatment resulted in the removal of over 30% of the total lignin content of the untreated chips. The majority of the lignin (28 to 32%) was solubilized during the solvent extraction using the 70% ethanol aqueous solution, and an additional 3 to 8% of the total lignin was removed during the subsequent hot water treatment.
[0094] The ratio of lignin to DM removed by the 70% ethanol treatment reached 35% in the first hour of treatment retention time at a temperature of 170° C. to 190° C. using the 100 ml and the 3 l packed-bed digesters. The lignin composition of the DM removed in the 3 l packed-bed digester during the second hour of treatment retention time increased by 5% and reached 50% after 4 hours. After 8 hours retention time in the reactor, the lignin content of the DM removed increased only by another 10% to reach 60%. In the 40 l batch digester, the ratio of lignin to DM removed varied from 30 to 48% when Salix dry chips were treated with 70% ethanol solvent. The proportion of the total lignin content in the untreated chips that was recovered in the 70% ethanol solvent using each of the three digesters varied over time. The high recovery of total lignin (32%±3) in 60 minutes using the smaller 100 ml digester reflected the higher rate of DM removal achieved with this digester. With the 3 l packed-bed digester, similar recovery was achieved within 200 to 240 minutes of treatment retention time. The amount of total lignin recovered using the 40 l batch digester varied between 22 and 44% of the initial lignin content of the Salix chips, corresponding to 6 to 13% of the initial DM loaded.
Example 2
Harvesting Precipitated Lignin by Dissolved Air Flotation
[0095] Lignin was precipitated from black liquor, and the precipitate harvested using a dissolved gas (air) flotation technique (“DAF”), as follows. Water was supersaturated with nitrogen by storage under elevated nitrogen pressure (2 barg) for at least 30 minutes. The water was allowed to leave the pressure vessel through a metering valve which regulated the flow rate of aerated water at 26 ml/min. Filtered black liquor (containing 12.4 g of lignin per liter) was pumped from the black liquor tank at various flow rates using a peristaltic pump. The aerated water and black liquor were mixed in a venturi mixing device and delivered into a flotation tank. Upon rapid mixing with the gassified water, the lignin in the black liquor precipitated, flocculated and floated to the surface of the tank. The supernatant passed under a dam and overflowed out of the tank. Based on the tank volume and the liquid flow rates, the residence time of the precipitate in the tank was calculated to be about three minutes. A paddle wheel device was used to move the lignin precipitate to one end of the precipitation tank. A porous moving belt of nylon mesh was used to lift the precipitated lignin out of the tank and drain off the supernatant liquid. A Perspex scraper was used to harvest the lignin from the belt and allow it to fall into the collection tank.
[0096] The relative flow rates of the aerated water and black liquor were varied, and the best yields of precipitated lignin were obtained where the water flow rate was at least three times the black liquor flow rate. Various venturi mixing devices were tested, and the best devices were found to be those which delivered the black liquor into the venturi through a small nozzle having a diameter of approximately 0.2 mm. This provided black liquor linear velocities of about 5 msec, implying that high shear rates are important to give good mixing. The venturi throat which gave best mixing had a diameter of 1 mm, which would give a linear flow rate for the mixture of 0.7 msec.
[0097] Use of the optimal conditions detailed above gave a lignin harvesting yield of 89% of theoretical. A further 3.6% of the lignin yield remained in suspension, and floated to the surface of the supernatant at later times. This suggests that a longer residence time of the precipitate in the tank would give a higher yield. The lignin sludge harvested from the belt was found to contain 4% w/v lignin. Pressing the sludge between two pieces of filter paper increased the lignin concentration to 20% w/v. This indicates that a belt press or similar device could be used to increase the solids content of the lignin sludge, and consequently facilitate drying of the sludge. After air-drying, the lignin harvested by the DAF technique disclosed herein yielded a light brown powder containing about 10% moisture.
[0098] The precipitation was found to occur optimally at a temperature of about 20° C. Temperatures above 35° C. gave a dense, sticky precipitate in poor yield.
Example 3
Large-Scale Harvesting of Lignin by DAF
[0099] Lignin was precipitated from black liquor, and the precipitate harvested by dissolved gas (air) flotation, on a larger scale as follows. Water was supersaturated with air by storage under compressed air pressure (2 barg). The water was allowed to leave the pressure vessel through a metering valve which regulated the flow rate of aerated water at 4.5 l/min. Filtered black liquor (containing 14.8 g of lignin per liter) was pumped from the black liquor tank at 1.4 l/min using a peristaltic pump, and the aerated water and black liquor were mixed in a venturi mixing device and delivered into a flotation tank. (The mixing ratio of aerated water to black liquor was 3.2:1) The venturi jet had a diameter of 2.5 mm, which would yield a black liquor linear velocity of 1.2 msec. The venturi throat had a diameter of 7 mm, implying a linear velocity for the mixture of 2.6 msec. The lignin in the black liquor precipitated, flocculated and floated to the surface of the tank. When the tank was full the floating lignin was allowed to stand for 30 mins and then harvested manually with a plastic scoop. The solids content of the lignin sludge varied in repeated experiments from 6-14% lignin w/v. The sludge was placed in a porous fabric bag and allowed to drain overnight. This typically increased the lignin solids content to about 23% w/v. The lignin sludge was then air-dried and sieved to yield a light brown powder containing about 10% moisture.
Example 4
Flocculation of an Aqueous Lignin Suspension
[0100] The ability of various additives to cause flocculation of lignin in an aqueous suspension of lignin was examined. The results of these studies are provided in Table 2, below.
[0000]
TABLE 2
Flocculation of lignin
Additive
Concentration
suspension
Ammonium
2
mM
−
chloride
4
mM
−
20
mM
++
40
mM
++
80
mM
++
200
mM
++
400
mM
++
Nonidet ™
0.4
ppm
−
P40
1
ppm
−
4
ppm
−
12
ppm
+
37
ppm
++
111
ppm
++
333
ppm
++
1,000
ppm
++
Ethanol
1%
v/v
−
2%
v/v
+
4%
v/v
+
9%
v/v
++
12%
v/v
++
17%
v/v
++
29%
v/v
++
38%
v/v
+
44%
v/v
*
50%
v/v
*
++: Flocculation
+: Partial flocculation
−: No flocculation
* Clear solution (precipitate dissolved)
[0101] Ammonium chloride at concentrations between 20 mM and 400 mM caused the lignin suspension to flocculate. Concentrations of greater than 400 mM were not tested. Ammonium sulfate and ammonium bicarbonate were also tested for their ability to cause flocculation of the lignin suspension. Ammonium sulfate gave similar results to ammonium chloride while ammonium bicarbonate had a weak effect at 400 mM and no effect at lower concentrations. Nonidet™ P40 at concentrations between 37 ppm and 1,000 ppm caused the lignin suspension to flocculate, with a weak effect being seen at 12 ppm and no effect at lower concentrations. Concentrations of greater than 1,000 ppm were not tested. Triton™ X-100 and Triton™ X-114 gave similar results to Nonidet™ P40. Sodium deoxycholate showed a weak effect at 1,000 ppm and no effect at lower concentrations. No effect was shown with sodium dodecyl sulfate, Tween™ 20, Tween™ 80, α-methyl mannoside, Brij™ 76, Brij™ 700, Lubrol™ PX or cetyltrimethylammonium bromide (CTAB).
[0102] Ethanol at concentrations between 29 and 9% v/v caused the lignin suspension to flocculate. At ethanol concentrations of 4% and 2% there was a weak effect, with no effect being seen at a concentration of 1% v/v. Ethanol at 38% v/v and higher caused the lignin precipitate to dissolve.
Example 5
Properties of Lignin Isolated from Salix as Determined by NMR
[0103] The lignin preparation submitted for NMR analysis was isolated by the treatment of 6.54 g (dry weight) of Salix schwerinii ‘Kinuyanagi’ dry chips with an aqueous solvent comprising 70% ethanol at 190° C. for 100 minutes in the 100 ml digester. The lignin recovered from the black liquor by precipitation and centrifugation was dissolved in DMSO-d6 for nuclear magnetic resonance spectroscopy analysis (as described in Ralph et al., 2006, Journal of Biological chemistry 281(13):8843) and compared to a commercially available Kraft lignin preparation (Sigma-Aldrich #370959). The 2D spectra of the lignin side chains from the NMR analysis for the Salix lignin isolated using the methodology described herein is shown in FIG. 5 , and the 2D spectra of the lignin side chains from the NMR analysis for a commercial Kraft lignin preparation is shown in FIG. 6 .
[0104] FIG. 5 illustrates the distribution of lignin side chains, including β-aryl ether (identified as “A”), phenylcoumaran (identified as “B”), resinol (identified as “C”), α-ethoxy-β-aryl ether (identified as A2) and cinnamyl alcohol side chains (identified as X1) retained in the lignin isolated using the modified ORGANOSOLV™ process described herein. FIG. 6 illustrates that minute quantities of β-aryl ether (identified as “A”) were present in the isolated Kraft lignin preparation, while there were no detectable quantities of phenylcoumaran, resinol, α-ethoxy-β-aryl ether or cinnamyl alcohol side chains. The lignin subunit distribution was quantified via volume-integration of the 2D contours in HSQC spectra, with minor corrections. The high ratio of β-aryl-ether (73%) and resinol (12%) subunits in the high grade isolated lignin preparation described herein is indicative of a higher degree of conservation of native structure. The destruction of the lignin side chains that occurs during Kraft pulping is shown by the absence of signal in the NMR spectra ( FIG. 6 ) indicating the presence of the native lignin side chains in the commercial Kraft lignin sample. These results demonstrate that lignin isolated using the methodology described herein retains a more “natural” structure than commercially available Kraft lignin, with the retention of a large proportion of the side chain structures that are important for lignin reactivity.
[0105] The lignin isolated according to methods described herein also demonstrated a higher methoxyl content than the commercially available Kraft lignin (30 to 40% as determined by volume-integration of the 2D contours in HSQC spectra, FIG. 5 ), making it desirably less likely to re-condense and more amenable toward chemical reaction.
[0106] The spectra shown in FIGS. 5 and 6 identify unresolved or unknown (non-lignin) components, such as saccharides, as “U.” These unresolved and unassigned constituents are contaminants in a lignin preparation. It is evident from the spectra illustrated in FIGS. 5 and 6 that the commercially available Kraft lignin preparation is highly impure and has a high level of contamination, while the lignin preparation of the present invention has considerably fewer contaminants. In fact, nearly all of the material detected in the commercially available Kraft lignin preparation is contaminant material. While contaminants are present in the lignin preparation of the present invention ( FIG. 5 ), those contaminants represent a far less significant proportion of the preparation.
[0107] Additionally, no sugars were detectable when the disclosed isolated lignin preparation was hydrolysed with concentrated sulfuric acid and the supernatant analysed by HPLC (High pressure liquid chromatography) on an ion exclusion column (BioRad Phenomenex Rezex™) with a lower detection limit of 0.2 g of sugars (glucose or xylose) per litre.
[0108] Lignin isolated from Salix schwerinii ‘Kinuyanagi’ using the above process was composed of about 80% syringyl (S) units and a ratio of syringyl:guaiacyl units of about 4:1 as quantified by volume integration of the 2D contours in HSQC spectra ( FIG. 7 ). This high ratio of S lignin is also reflected by the relatively high content of O-methoxyl groups (40%, FIG. 5 ).
Example 6
Additional Properties of Lignin Isolated from Salix
[0109] The molecular weight average and molecular weight distribution of several samples of the disclosed high grade isolated lignin were calculated from the gel filtration elution profile of the lignin preparation ( FIG. 8 ) on a Superdex Peptide column (GE Healthcare #17-5176-01 10/300 GL, as described by Reid (1991), Biotechnol. Tech, 5:215-218). Lysozyme, aprotinin and 3,4-dimethylbenzyl alcohol were used as standards for calibration and therefore these molecular weights should be taken as relative values. Isolated lignin samples were prepared as described above using lignin harvested by precipitation and centrifugation (Samples BJL2-5) and lignin harvested using the DAF process described herein (Sample BJLD) were dissolved at 0.5 mg/ml in 50% ethanol/50 mM NaOH for the gel filtration analysis. Commercially available lignin samples were prepared for comparative analysis, including a Kraft lignin preparation (Sigma-Aldrich #370959) and an ORGANOSOLV lignin preparation (Sigma-Aldrich, cat. No. 37, 101-7). Each sample was analysed in duplicate with an injection volume of 200 μl. The results are shown in FIG. 8 and summarized in Table 3, below.
[0110] The majority of the lignin (at the elution peak) in the isolated lignin samples prepared as disclosed herein and harvested by precipitation and centrifugation (samples BJL2-5), had an average molecular mass of approximately 6,500 g/mol. This molecular mass is about 2 to 3 times greater than the molecular mass of the majority of the lignin (at the elution peak) in the commercially available Kraft lignin composition (Sigma-Aldrich #370959; molecular mass 1,942 g/mol) or the commercially available ORGANOSOLV lignin composition (Sigma-Aldrich, cat. No. 37, 101-7; molecular mass 2,627 g/mol). The weight average molecular mass of the isolated lignin samples BJL2-5 was in excess of 5,200, while the weight average molecular mass of the commercial Kraft lignin preparation was approximately 2,229 and the weight average molecular mass of the commercial ORGANOSOLV lignin preparation was approximately 3,000. These values are in agreement with previously published studies using gel filtration for molecular weight analysis of Kraft and ORGANOSOLV lignin preparations from hardwood (Kubo and Kadla (2004) Macromolecules, 37:6904-6911; Cetin and Ozmen (2002) Proceedings of ICNP ; Glasser et al. (1992) J. Wood Chem. and Technol. 13:4, 545-559), with slightly higher polydispersity (PD) values. The isolated lignin sample prepared as disclosed herein and harvested using the DAF process described here (Sample BJLD) had an average molecular mass of over 7,200 and a weight average molecular mass of over 5,500.
[0000]
TABLE 3
Molecular Mass
g/mol at elution peak
Weight
Poly-
(n = 2)
Average
dispersity
Lignin Sample
Avr
StDv
(Mw)
(PD)
BJL2
5,933
0.668
4,871
4.1
BJL3
6,374
0.844
5,384
3.0
BJL4
6,800
0.810
5,372
3.9
BJL5
7,172
0.285
5,450
3.9
BJL Average
6,570
0.535
5,269
3.7
BJLD
7,271
0.049
5,712
3.7
Kraft
1,942
0.218
2,229
3.5
ORGANOSOLV
2,627
0.070
2,992
3.3
Example 7
Reactivity of High Grade Lignin Isolated from Salix
[0111] The reactivity of the disclosed lignin was assessed by measurement of the total and phenolic hydroxyl groups and compared with the commercial Kraft and ORGANOSOLV lignin preparations (Table 4, below). The total amount of hydroxyl functional group in each lignin sample is expressed as a potassium hydroxide equivalent and was measured using standard testing method (ASTM D4274-05). The amount of phenolic hydroxyl groups in each lignin sample was assessed by differential spectrophotometry as described by Wexler (Analytical Chemistry 36(1) 213-221 (1964)) using 4-hydroxy-3-methoxybenzyl alcohol as a calibration standard. In this analysis, the amount of phenolic hydroxyl is relatively low for all the lignin samples analysis and the total amount of hydroxyl measurements do not vary greatly among the samples (Table 4). However, the ratio of phenolic to total hydroxyl is lower in the disclosed lignin samples (BJL2, BJL-5 and BJLD) as compared with the Kraft and ORGANOSOLV commercial lignin preparations.
[0000]
TABLE 4
Hydroxyl Numbers
mmol/g
Ratio
Lignin Sample
Total
Phenolic
Phenolic:Total
BJL2
6.06
0.33
0.054
BJL5
6.23
0.28
0.044
BJLD
5.40
0.29
0.054
ORGANOSOLV
5.78
0.38
0.066
Kraft
6.41
0.40
0.062
Example 8
Production of Urethane Foam Using Isolated Lignin of the Present Invention
[0112] Rigid polyurethane (PU) foam was produced using lignin derived from Salix and isolated as described herein. The foam was tested and demonstrated excellent thermal conductivity and density properties. The density of the rigid PU foam produced using isolated lignin was 0.62 g/cm 3 compared to a density of rigid PU foam produced using conventional feedstocks of 0.05 g/cm 3 . The thermal conductivity of the rigid PU foam produced using isolated lignin was 0.030 to 0.032 compared to a thermal conductivity of rigid PU foam produced using conventional feedstocks of 0.035. The thermal degradation temperature of the rigid PU foam produced using isolated lignin was 295° C.; the compression strength was 0.5 MPa; and the compression modulus was 19 MPa.
[0113] While the present invention has been described with reference to the specific embodiments thereof, it should be understood by those skilled in the art that various changes may be made and equivalents may be substituted without departing from the true spirit and scope of the invention. In addition, many modifications may be made to adapt a particular situation, material, composition of matter, method, method step or steps, for use in practicing the present invention. All such modifications are intended to be within the scope of the claims appended hereto.
[0114] To the extent that the claims appended hereto express inventions in language different from that used in other portions of the specification, applicants expressly intend for the claims appended hereto to form part of the specification and the written description of the invention, and for the inventions, as expressed in the claims appended hereto, to form a part of this disclosure.
[0115] All of the publications, patent applications and patents cited in this application are herein incorporated by reference in their entirety to the same extent as if each individual publication, patent application or patent was specifically and individually indicated to be incorporated by reference in its entirety. | Lignin polymers having distinctive properties, including a generally high molecular weight and generally homogeneous size distribution, as well as preservation of native reactive side groups, are isolated by solvent extraction of plant materials. Methods for isolation of lignin polymers, and for use of the isolated lignin polymers are disclosed. Compositions containing lignin isolated from plant materials, such as carbon fiber composites, resins, adhesive binders and coatings, polyurethane-based foams, rubbers and elastomers, plastics, films, paints, nutritional supplements, food and beverage additives are disclosed. Xylose and xylose derivatives, furfural, fermentable sugars, cellulose and hemi-cellulose products may be used directly or further processed. The lignin polymers and other plant-derived products disclosed herein may be produced in abundance at low cost, and may be used as substitutes for feedstocks originating from fossil fuel or petrochemical sources in the manufacture of various products. | 3 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a novel pigment which is employed in a coloring agent for a paint, a plastic, a cosmetic or the like, and a process for producing the same.
2. Description of the Related Art
A pearl mica pigment, for instance, has been known which is employed in a top coat paint for an automobile. This pearl mica pigment has a construction in which TiO 2 is coated on the entire surface of mica, and it is used in a decorative painting which utilizes the interference colors resulting from the high refractive index of the TiO 2 .
The pearl mica pigment produces a variety of interference colors through the thickness variation of the TiO 2 layer formed on the surface of the mica. When the TiO 2 is coated in an amount of from 26 to 40% by weight with respect to the product, the pearl mica pigment produces gold. When the amount is from 40 to 50% by weight, it varies to produce red, blue and green as the thickness of the TiO 2 layer increases. When the amount is from 50 to 60% by weight, it produces strong interference colors.
Although the pearl mica pigment has the pearly glossy effect and a variety of the interference colors, it always looks like white in the appearance. Hence, no pearl mica pigment has been available which produces a vivid color in the appearance.
Consequently, colored pigments such as iron oxide, iron blue, chromium oxide and carbon black have been added to the pearl mica pigment so as to attain a variety of colors in the appearance. However, when a plurality of these colored pigments are mixed to use, the inherent pearly glossy effect and interference colors of the pearl mica pigment are impaired, thereby deteriorating the decorativeness.
Therefore, the pearl mica pigment has been investigated in order to improve its decorativeness, and the following 3 representative methods have been reported so far: Japanese Unexamined Patent Publication (KOKAI) No. 19,666/1986, Japanese Unexamined Patent Publication (KOKAI) No. 164,653/1983, and Japanese Unexamined Patent Publication (KOKAI) No. 212,422/1984.
However, the method disclosed in Japanese Unexamined Patent Publication (KOKAI) No. 19,666/1986 has a problem that it can produce only red and black pearl mica pigments. The method disclosed in Japanese Unexamined Patent Publication (KOKAI) No. 164,653/1983 has a problem that it can produce only blue, bluish black, black and brownish black pearl mica pigments.
The method disclosed in Japanese Unexamined Patent Publication (KOKAI) No. 212,422/1984 can color the pearl mica pigment in blue, green, gold, reddish purple. However, in this method, the pearl mica pigment should be heated and reduced in a hydrogen gas atmosphere at a high temperature of from 500° to 1,000° C. Since the thickness of the TiO 2 layer is extremely thin, there is an anxiety for reducing the entire TiO 2 layer when reducing at the high temperature of from 500° to 1,000° C. Accordingly, it is hard to control a component ratio of titanium with respect to oxygen in a particle diameter direction of the mica or the thickness-wise direction of the TiO 2 layer. In addition, since the particles of the pearl mica pigments are sintered to aggregate and solidify at the high temperature, no fine powder pigment which is dispersed into its primary particles can be obtained. Hence, it is necessary to employ a special apparatus in order to maintain the powder state.
One might think of forming a titanium oxide layer on the mica particles themselves by sputtering titanium in an oxygen gas stream under decompression. However, the oxygen reacts with the titanium target to oxidize the target, and the sputterability through an oxygen gas is considerably small when compared with those through an argon gas and a helium gas. Hence, such a method is not practical. In addition, it is extremely hard to control the component ratio of titanium with respect to oxygen in the particle diameter direction of the mica or the thickness-wise direction of the TiO 2 layer.
However, the pearl mica pigment is poor in the covering power and the metallic glossy effect. Accordingly, there have been proposed a variety of improved versions.
For example, Japanese Unexamined Patent Publication No. 161,055/1982 (KOKAI) discloses a pigment which includes a metallic coating layer formed on the entire surface of mica by plating.
Japanese Unexamined Patent Publication (KOKAI) No. 108,267/1989 which was applied by the present applicants discloses a pigment which includes metallic glossy dots formed on the surface of a pearl mica pigment in a scattering manner.
A pigment is commercially available from Shiseido Co., Ltd. under a trade name of "Infinite Color." The pigment includes a layer of oxides of titanium exhibiting low orders of oxidation states (hereinafter simply referred to as "low order oxides of titanium") which are formed on the entire surface of mica, and a TiO 2 layer which is further formed on the entire surface of the layer of the low order oxides of titanium.
The pigment disclosed in Japanese Unexamined Patent Publication (KOKAI) No. 161,055/1982 has a sharp metallic glossy effect because the entire surface of the mica is covered with the plated metal. However, it does not produce interference colors. Accordingly, it does not produce no deep effect.
The pigment disclosed in Japanese Unexamined Patent Publication (KOKAI) No. 108,267/1989 operates through the reflection of the metal and scattering as well as the interference of the TiO 2 , and it produces both the interference colors and the metallic glossy effect. However, it produces the interference colors in an insufficient strength.
The commercially available "Infinite Color" produces the interference colors in a strength in a certain degree. However, it suffers from the insufficient metallic glossy effect and covering power.
Further, a metallic paint has been used widely in a top coat paint for an automobile. This metallic paint contains a foil-like aluminum powder. The metallic paint is favorable because of its high covering power. However, it is hard to make a metallic paint which produces a light color because the aluminum does not have such a high brightness.
Hence, a metallic paint comprising the pearl mica pigment which includes the TiO 2 layer formed on the surface of the mica has been developed recently, and it is employed in practical applications. This metallic paint produces the pearly glossiness resulting from the mica as well as the interference colors resulting from the high refractive index of the TiO 2 . Even when the paint color is a light one, the metallic paint produces a glossy metallic effect in the appearance.
However, the metallic paint comprising the pearl mica pigment lacks the covering power, and it is often hard to carry out painting with the metallic paint under the two-coat-one-bake system, the current automobile painting process. In addition, the thus obtained paint film suffers from an insufficient metallic glossy effect when it is viewed in an oblique direction (i.e., in a shade direction).
Japanese Unexamined Patent Publication (KOKAI) No. 104,673/1989 discloses a metallic paint comprising a pigment in which a glossy metal is deposited on a part of a mica surface. This metallic paint, however, produces a metallic glossy effect only, and it is insufficient in the decorativeness.
The present applicants applied for a patent under Japanese Unexamined Patent Publication (KOKAI) No. 108,267/1989. The publication discloses a pigment which improves the above-mentioned shortcomings. The pigment includes metallic glossy dots which are formed on a surface of a pearl mica pigment in a scattering manner. A metallic paint comprising this pigment produces an enhanced metallic glossy effect when viewed in an oblique direction (i.e., in a shade direction), and it exhibits an improved covering power. However, the covering power and the interference colors of the metallic paint are still insufficient. Accordingly, there has been longed for a further improvement in the metallic paint.
Moreover, it is required for an automobile paint or the like, which is to be painted on an external metal surface particularly, to have an excellent weather resistance which enables the appearance of the paint not to change as long as a few years substantially though the paint is exposed to various weather conditions. This weather resistance is not only affected by the weather resistance of its resin components as a matrix, but also it is greatly affected by a pigment which are contained in the paint.
There have been proposed a variety of methods for improving the weather resistance of a TiO 2 pigment which has been used widely as a white pigment.
For example, in U.S. Pat. No. 2,242,320, chromium naphthenate is used as a covering material for a surface of the TiO 2 pigment.
In U.S. Pat. No. 2,242,322, in order to improve the resistance against the chalking and discoloring, the TiO 2 pigment is colored by combining 0.5% of chromium in a form of oxides, 2.0% of zirconium silicate and 1.0% of alumina on the calcined TiO 2 pigment.
In U.S. Pat. Nos. 2,226,142 and 2,062,137, chromium compounds are added to the TiO 2 pigment in order to improve the weather resistance before calcining it.
In U.S. Pat. No. 2,045,836, TiO 2 is precipitated in the presence of a chromic acid so as to generate the TiO 2 pigment which includes chromate ions, thereby improving the weather resistance.
In U.S. Pat. No. 2,231,268, a pigment production process is disclosed. The production process includes a preparing step of preparing calcined TiO 2 , which includes small amounts of aluminum (from 0.25 to 2% as Al 2 O 3 ) and chromium (from 0.01 to 2% as Cr 2 O 3 ), and a drying step.
However, the pearl mica pigment which includes the mica particles coated with the TiO 2 is a more complex substance than the simple TiO 2 pigment is. Hence, the methods or techniques employed for stabilizing the TiO 2 pigment are useless or insufficient to give the stability to the pearl mica pigment. This is because there occurs reactions at the boundaries between the mica and the TiO 2 , and it is also because the TiO 2 itself reacts.
Hence, there have been proposed a variety of methods for improving the weather resistance of the pearl mica pigment.
For instance, West Germany Laid-Open Patent Publication No. 1,467,468 sets forth an advantageous effect of chromium hydroxide coating layer which is formed on mica covered with anatase type TiO 2 .
West Germany Laid-Open Patent Publication No. 2,852,585 sets forth a similar advantageous effect of chromium hydroxide coating layer for mica which is covered with rutile type TiO 2 .
The primary object of these two German patent publications is to obtain a transparent pearl mica pigment.
In Japanese Unexamined Patent Publication (KOKAI) No. 34,527/1972, a method is disclosed in which a pearl mica pigment is treated with methacrylate chromium (III) chloride. When the methacrylate chromium (III) chloride remains without being hydrolyzed substantially on the pearl mica pigment, there arises an advantageous effect of this treatment. The purpose of the treatment is said to give "an excellent resistance against varying conditions" to a coating film comprising this pigment, however, the advantageous effect is available only for the case where the coating film is exposed to moisture.
In Japanese Examined Patent Publication (KOKOKU) No. 3,345/1985, a pearl mica pigment is disclosed, and it is formed as follows. A thin TiO 2 film is precipitated on a mica surface, and thereafter SnO 2 and TiO 2 are coated thereon by turns in this order. After burning the thus coated mica at a temperature up to 1,000° C., it is further coated with an insoluble chromium compound, and it is burned again to form the rutile type TiO 2 on the mica surface.
Even when the conventional pearl mica pigment is mixed with various paints and plastics, it cannot be employed in practical applications because it has an insufficient weather resistance. Therefore, the present inventors carried out the chromium (III) oxide treatments on the outermost surface of the conventional pearl mica pigment in accordance with the above-mentioned related arts, i.e., West Germany Laid-Open Patent Publication No. 1,467,468, West Germany Laid-Open Patent Publication No. 2,852,585, Japanese Unexamined Patent Publication (KOKAI) No. 34,527/1972 and Japanese Examined Patent Publication (KOKOKU) No. 3,345/1985. However, the weather resistance of the conventional pearl mica pigment could not be improved at all.
SUMMARY OF THE INVENTION
It is a primary object of the present invention to provide a novel pearl mica pigment which produces the interference colors and the metallic glossy effect in sufficient strengths and to increase the covering power of the pearl mica pigment.
It is a secondary object of the present invention to provide a production process which enables to produce the novel pearl mica pigment in a variety of colors with ease.
It is a tertiary object of the present invention to provide a metallic paint which comprises the novel pearl mica pigment and which produces the interference colors and the metallic glossy effect in sufficient strengths and to increase the covering power of the metallic paint.
It is a quaternary object of the present invention to improve the weather resistance of the novel pearl mica pigment.
The present inventors have made research and development in order to improve the strengths of the interference colors and the covering power of the pigment which is disclosed in Japanese Patent Publication (KOKAI) No. 108,267/1989. As a result, a first aspect of the present invention has been completed. Namely, there is provided a pigment according to the first aspect of the present invention which comprises:
a transparent or semi-transparent scaly substrate;
a TiO 2 layer coated on an entire surface of the substrate;
light absorbing portions formed on a surface of the TiO 2 layer in a scattering manner and including low order oxides of titanium; and
glossy portions formed on a surface of the TiO 2 layer in a scattering manner and having a metallic glossy effect.
The substrate is a base of the present pigment. A transparent or semi-transparent scaly one such as mica, glass foil, molybdenum disulfide, Fe 2 O 3 , MIO or the like can be employed as the substrate. It is especially preferred to employ the mica which is produced in a scaly crystalline substance naturally. It is also possible to employ natural mica such as muscovite, biotite, phlogopite or the like and synthetic mica.
The substrate ordinarily has a length of from 1 to 75 micrometers, preferably from 5 to 40 micrometers, and it ordinarily has a thickness of from 0.03 to 0.3 micrometers, preferably from 0.10 to 1.0 micrometers. In addition, the substrate ordinarily has a specific surface of from 1 to 10 m 2 /g, preferably from 2 to 6 m 2 /g, which is determined by the BET equation.
The TiO 2 layer is identical with that of the conventional pearl mica pigment, and it is coated on the entire surface of the substrate. Depending on a thickness of the TiO 2 layer, the pigment can produce the interference colors in a variety of hues.
One of the major features of the present pigment is that it includes the light absorbing portions and glossy portions which are formed on the surface of the TiO 2 layer in a scattering manner. The light absorbing portions include low order oxides of titanium. The low order oxides of titanium differ from the colorless and transparent TiO 2 in that they reflect and absorb light. Accordingly, the low order oxides of titanium have their own substance colors which vary from blue, brown to black. The substance colors are compounded with the interference colors resulting from the TiO 2 to produce a variety of colors. These light absorbing portions can be formed by reducing the TiO 2 layer locally, or they can be deposited on the surface of the TiO 2 layer in a scattering manner. In particular, as later described, it is especially convenient to form the light absorbing portions simultaneously with the formation of the glossy portions.
The glossy portions have a metallic glossy effect, and it can be formed with titanium, zirconium, tungsten, nickel, aluminum, silver, platinum, gold or the like by a chemical method, such as electroplating, electroless plating or the like, and a physical method, such as sputtering, vapor deposition, ion plating or the like. For instance, as later described, when titanium is deposited on the TiO 2 layer by sputtering, part of the TiO 2 layer is reduced simultaneously with the titanium deposition. Thus, the light absorbing portions which include low order oxides of titanium can be formed simultaneously with the formation of the glossy portions.
It is preferred to form the light absorbing portions and glossy portions so as to occupy from 0.03 to 98% of an entire surface area of the TiO 2 layer in a total projection area on the TiO 2 layer. When they occupy less than 0.03%, the covering power of the pigment decreases. When they occupy more than 98%, the pigment produces the interference colors in a lesser strength. The light absorbing portions and the glossy portions can be formed on the TiO 2 layer independently of each other, or the glossy portions can be formed so as to overlap the light absorbing portions. As later described, a surface treatment can be carried out onto the present pigment in order to give it a weather resistance. The surface treatment can be a chromium, alumina or zirconia treatment.
As illustrated in FIG. 2, in the present pigment, a reflection light "A," for instance, which is reflected by the surface of the TiO 2 layer 101, and a reflection light "B," which is reflected by the boundary between the TiO 2 layer 101 and the substrate 101, interfere each other. Accordingly, the present pigment produces an interference color which depends on the product of the TiO 2 layer thickness and the TiO 2 layer refractive index (i.e., "TiO 2 layer thickness"×"TiO 2 layer refractive index"). Further, part of the incident light is absorbed by the light absorbing portions 102, and thereby a reflection light "C" produces the substance colors of the light absorbing portions 102. Furthermore, a reflection light "D," which is reflected by the glossy portions 103, produces a metallic glossy effect. Therefore, the present pigment can produce deep and unique colored metallic hues in which these reflection lights, interference lights, absorption lights and metallic glossy effects are compounded.
Generally speaking, the more the light passes through a pigment, the smaller the covering power of the pigment becomes. In the present pigment, part of a light "F," which passes through the substrate 100, is absorbed by the light absorbing portions 102 which are disposed on the opposite side. Hence, the amount of the light which passes through the present pigment is less than the amount of the light which passes through the conventional pearl mica pigment, and consequently the covering power of the present pigment improves. In addition, when the light is viewed in a shade direction, the present pigment produces vivid colors because the light absorbing portions 102 absorb the light to cause the irregular reflections less. As a result, the contrast is remarkable between the light viewed in the front direction and the light viewed in a shade direction, and accordingly the present pigment exhibits a favorable "flip-flop" characteristic.
Moreover, a light "E," which passes through a pigment and which is reflected by a base or a surface of the other pigment to re-enter the original pigment, are re-combined with the reflection light "A" and the reflection light "B" to weaken the interference colors. However, in the present pigment, part of the light, which passes through the substrate 100, is absorbed by the light absorbing portions 102 which are disposed on the opposite side, and part of the light, which is reflected by a base or a surface of the other present pigment to re-enter the original present pigment, is also absorbed by the light absorbing portions 102. Consequently, the amount of the reflection light "E" is reduced when compared with that of the conventional pearl mica pigment. Thus, the present pigment inhibits the interference colors from weakening, and it produces strong interference colors.
According to the present pigment, it is possible to obtain the metallic glossy effect, the strong interference colors and the color production resulting from the substance colors of the light absorbing portions. In addition, the present pigment exhibits a great covering power. Therefore, the present pigment is extremely useful for an automobile top coat paint.
Further, the present inventors have continued the research and development in order to solve the problems associating with the conventional pearl mica pigment and the problems associating with the production process therefor, and they have found a phenomenon that the TiO 2 layer is reduced to the low order oxides of titanium when the surface of the conventional pearl mica pigment is coated with metallic titanium by sputtering under a vacuum condition.
In accordance with this method, it is unnecessary to heat and reduce the conventional pearl mica pigment in a hydrogen gas at the high temperature of from 500° to 1,000° C. In addition, it is possible not only to color the conventional pearl mica pigment in a variety of colors such as gold, silver, red, blue, green or the like, but also to incorporate the interference colors into the conventional pearl mica pigment. Thus, the present inventors found that it is possible to produce a novel pigment having new decorativeness, which has not be available so far, with this method.
As for the method for coating the surface of the conventional pearl mica pigment, vacuum deposition, ion plating, CVD (chemical vapor deposition) can be used in addition to the above-mentioned sputtering. However, since the target of the coating is a powder, these methods somewhat suffer from problems which associate with the constructions of the apparatuses, the control of the metallic titanium coating amount or the like.
There is provided a process for producing a pigment according to a second aspect of the present invention which comprises the steps of:
supplying a pigment which comprises a transparent or semi-transparent scaly substrate coated with a TiO 2 layer under a decompression and heating condition; and
coating said pigment with metallic titanium in a scattering manner by sputtering, thereby reducing part of the TiO 2 layer to low order oxides of titanium.
It is preferred to carry out the sputtering at a temperature of 200° C. or less in the coating step. When it is carried out at a temperature of more than 200° C., the pigment tends to aggregate intensely and to become massive. As a result, it is impossible to coat the pigment with the metallic titanium uniformly.
In addition, it is preferred to carry out the present production process by circulating the pigment through a powder decompression and heating treatment station, a fluidized bed sputtering station and a fluid mill powder dispersing treatment station, thereby carrying out the metallic titanium coating by sputtering repeatedly.
A novel pigment obtained by the present production process has a construction similar to that of the pigment according to the first aspect of the present invention, and it operates similarly thereto. Additionally, the novel pigment is characterized by a varying component ratio of titanium with respect to oxygen in the thickness-wise direction of the TiO 2 layer.
As for the pigment which comprises a transparent or semi-transparent scaly substrate coated with the TiO 2 layer, a conventional pearl mica can be used, for instance. The conventional pearl mica pigment includes the transparent or semi-transparent scaly substrate which has a length of from 1 to 75 micrometers, preferably from 5 to 40 micrometers, and a thickness of from 0.03 to 0.3 micrometers, preferably from 0.10 to 1.0 micrometers, and which is coated with the TiO 2 layer entirely.
In the pigment, the TiO 2 can be contained in an amount of from 10 to 60% by weight with respect to the substrate. Depending on a thickness of the TiO 2 layer, the interference colors such as silver, blue, green, red, reddish purple, gold or the like can be given to the pigment.
The novel pigment produced by the present production process has the hues which are in the same family of the hues of a raw material, i.e., the conventional pearl mica pigment. The less the metallic titanium is sputtered, the brighter the novel pigment becomes. On the other hand, the more the metallic titanium is sputtered, the darker the novel pigment becomes. As for the sputtering amount of the metallic titanium, it is preferred to sputter the metallic titanium in an amount of from 1 to 30% by weight with respect to the raw material. When the sputtering amount is less than 1% by weight, the coloring effect is hardly appreciated. When the sputtering amount is more than 30% by weight, the novel pigment produces a metallic gray which is not a chromatic color. Hence, it is not preferred to coat the raw material in the sputtering amount.
The novel pigment produced by the present production process can be used as a new colored pigment which is adapted for paints and plastics for the applications such as exterior construction materials, interior construction materials, home electric products, automobiles, ships or the like.
Furthermore, as a result of the research and development which have been made by the present inventors in order to improve the strengths of the interference colors and the covering power of the pigment which is disclosed in Japanese Patent Publication (KOKAI) No. 108,267/1989. The present inventors have completed a third aspect of the present invention. Namely, there is provided a metallic paint according to the third aspect of the present invention which comprises a pigment, the pigment including:
a transparent or semi-transparent scaly substrate;
a TiO 2 layer coated on an entire surface of the substrate;
light absorbing portions formed on a surface of the TiO 2 layer in a scattering manner and including low order oxides of titanium; and
glossy portions formed on a surface of the TiO 2 layer in a scattering manner and having a metallic glossy effect.
In addition to the above-described novel pigment, the present metallic paint can further include the other components such as a resin which constitutes a matrix, a pigment, an additive or the like. As for the resin, it is possible to use a variety of resins, which are employed in the conventional metallic paint, such as an acrylic resin, a melamine resin, a polyester resin or the like. As for the pigment, it is possible to constitute it with the novel pigment only, or it is also possible to mix the novel pigment with the conventional pearl mica pigment or a variety of organic pigments and inorganic pigments. In addition, it is possible to use a variety of additives such as a dispersing agent, a plasticizer, a surface active agent or the like which have been employed conventionally.
Here, it is preferred to include the above-described novel pigment in an amount of from 1 to 20 parts by weight with respect to 100 parts by weight of the solid components in the present metallic paint. When the amount is less than 1 parts by weight, the advantageous effect of the novel pigment inclusion is appreciated insufficiently. When the amount is more than 20 parts by weight, the dispersion stability of the paint decreases, thereby decreasing the vividness of the images on the paint film and deteriorating the operability in painting.
Moreover, the present inventors have further continued the research and development, and they have found that it is possible to give an extremely good weather resistance to the conventional pearl mica pigment as follows. The surface of the conventional pearl mica pigment is first coated with chromium (III) hydroxide, and thereafter low order oxides of titanium and metallic titanium are formed by sputtering on the surface the thus coated pearl mica pigment in a scattering manner, and then the resulting pearl mica pigment is further coated with chromium (III) hydroxide. As a result, a fourth aspect of the present invention has been completed. Namely, there is provided a process for producing a novel and weather resistant pigment according to a fourth aspect of the present invention which comprises the steps of:
a first coating step of coating a surface of a transparent or semi-transparent scaly substrate with chromium (III) hydroxide, the substrate coated with a semi-transparent layer which includes rutile type TiO 2 mainly;
a step of forming low order oxides of titanium and metallic titanium on a resulting substrate in a scattering manner; and
a second coating step of coating a surface of a resulting substrate with chromium (III) hydroxide.
The transparent or semi-transparent scaly substrate can be identical with that of the novel pigment according to the first aspect of the present invention. The rutile type TiO 2 layer can be coated on the substrate in a manner as set forth in U.S. Pat. No. 4,038,099.
In the present production process, the first coating step is carried out with chromium (III) hydroxide. This step can be carried out as follows. A dilute solution including a soluble chromium (III) compound such as chromium chloride and chromium sulfate is hydrolyzed, thereby coating the substrate particles with a thin film of the resulting chromium (III) hydroxide. The dilute solution of the soluble chromium (III) compound contains chromium in an amount of from 0.5 to 5% by weight, preferably from 1 to 2.5% by weight.
In the first coating step, the substrate is first added to water at room temperature to make a slurry in a concentration of from 5 to 15% by weight, and a pH of the resulting slurry is kept in a range of from 5.5 to 6.5 with a diluted sulfuric acid or the like. Then, a chromium (III) compound solution is added to the slurry while stirring the slurry. The addition of the chromium (III) compound solution takes from 0.1 to 2.0 hours, preferably from 0.25 to 0.75 hours, and the addition speed is constant preferably. It is also preferred to keep a pH of the slurry at 6.0 approximately with a dilute potassium hydroxide or the like.
Also in the first coating step, the chromium (III) compound is added to the slurry in a sufficient amount of from 0.2 to 1.0% by weight as chromium with respect to a total amount of the substrate coated with the rutile type TiO 2 layer, preferably from 0.3 to 0.6% by weight. After adding all the chromium (III) compound solution, the slurry is filtered. The resulting cake is washed, and it is dried at a temperature of from 90° to 120° C. for 1 to 2 hours.
Then, in accordance with the production process according to the second aspect of the present invention, metallic titanium is deposited on the TiO 2 layer. The TiO 2 layer is reduced simultaneously with the deposition of the metallic titanium, and thereby the low order oxides of titanium can be formed in a scattering manner.
As aforementioned in the second aspect of the present, it is preferred to sputter the metallic titanium (Ti) in an amount of from 1 to 30% by weight with respect to the substrate. It is further preferred to sputter the metallic titanium in an amount of from 2 to 20% by weight with respect to the substrate. When the sputtering amount is less than 2% by weight, the coloring power, the covering power and the metallic glossy effect of the novel pigment decrease sharply. Hence, such a novel pigment cannot be not used in practical applications. When the sputtering amount is more than 20% by weight, the novel pigment produces an improved covering power and an improved metallic glossy effect, but it suffers from a decreased coloring power and increased production costs.
As later described in the "Sixth Preferred Embodiment" section, when the metallic titanium is sputtered in an amount of 2% by weight, the low order oxides of titanium are produced in an amount of 2.2% by weight, and the metallic titanium is produced in an amount of 0.5% by weight. In this case, the low order oxides of titanium which form the light absorbing portions and the metallic titanium which forms the metallic glossy portions occupy approximately 0.05% of an entire surface area of the TiO 2 layer in a total projection area. On the other hand, when the metallic titanium is sputtered in an amount of 20% by weight, the low order oxides of titanium are produced in an amount of 6.7% by weight, and the metallic titanium is produced in an amount of 14.7% by weight. In this case, the light absorbing portions and the metallic glossy portions occupy approximately 95% of an entire surface area of the TiO 2 layer in a total projection area. Thus, when the metallic titanium is sputtered in an amount of from 2 to 20% by weight, the novel pigment can be made into one which has all the characteristics such as the coloring power, the covering power and the metallic glossy effect which can be applicable to a practical usages.
In other words, it is preferred to form the light absorbing portions and the metallic glossy portions so as to occupy from 0.03 to 98% of an entire surface area of the TiO 2 layer in a total projection area. When they occupy less than 0.03%, the novel pigment exhibits a decreased covering power. When they occupy more than 98%, the novel pigment produces the interference colors in a lesser strength.
The first coating step and the second coating step can be carried out as follows. The substrates which have been undergone the predetermined treatments are suspended in an aqueous solution, and they are coated with chromium (III) hydroxide and/or chromium (III) phosphate. The coating condition of these coating steps can be varied in a wide range. However, it is only a preferred condition that insoluble chromium (III) compounds are generated in the suspension by hydrolysis or reduction at a speed so as to deposit on the surface of the substrates continuously and without forming free nuclei in a significant amount.
The insoluble chromium (III) compounds can be generated by starting with the soluble chromium (III) compound. When the soluble chromium (III) compound is adapted for a raw material, hydroxyl ions or phosphate ions are included in the suspension of the substrates in a necessary amount so as to precipitate the chromium (III) hydroxide or chromium (III) phosphate, and the chromium (III) compound solution is added to the suspension slowly to generate the chromium (III) hydroxide or chromium (III) phosphate layer. Further, the chromium (III) compound is included in the suspension of the substrates, and the hydroxyl ions or phosphate ions are added to the suspension slowly to generate the chromium (III) hydroxide or chromium (III) phosphate layer. Furthermore, the chromium (III) compound solution and a solution containing the ions to be precipitated can be added to the suspension of the substrates at the same time. If such is the case, a pH of the suspension is kept at a constant value while adding the solutions. Moreover, the chromium (III) hydroxide or chromium (III) phosphate layer can be generated in situ by a chemical reaction such as a homogeneous hydrolysis in the substrates suspension which contains the soluble chromium (III) compound.
Likewise, the insoluble chromium (III) compounds can be formed of chromium (III) ions or chromium (IV) compounds in situ. For instance, the insoluble chromium (III) compounds can be generated in situ by admixing a chromium (IV) compound solution and a reducing agent such as hydrazine, hydroxylamine or the like to the suspension of the substrates one component by one component, or by slowly admixing both of them thereto at the same time.
In the first and second coating steps, it is necessary to keep a pH of the suspension of the substrates at approximately 3.0 or more, more preferably in a range of from 4.5 to 9.0. When adjusting a pH of the suspension of the substrates, which has been strongly acidified, by independently adding an acidic chromium (III) compound solution, any base can be used in principle. For instance, it is preferred to use ammonium (either in a solution form or a gas form), a sodium hydroxide solution, a potassium hydroxide solution or the like.
In order to supply the chromium (III) ions, either chromium (III) compound or chromium (IV) compound can be used in general. In particular, it is preferred to use CrCl 3 , a chromium aluminate solution, potassium dichromate or the like. When precipitating the chromium (III) phosphate, not only orthophosphoric acid, but also primary, secondary and tertiary orthophosphoric acids and polymerized phosphates can be used. As for an appropriate example, the following are available in addition to phosphoric acid: i.e., KH 2 PO 4 , NaH 2 PO 4 . 12H 2 O, Na 3 PO 4 .12H 2 O, Na 4 P 2 O 7 .7H 2 O and (NaPO 3 ) x .
The coating of the chromium (III) hydroxide or chromium (III) phosphate layer can be carried out at any temperature of from a freezing point to a boiling point of the suspension of the substrates. The present inventors have found that the second coating can be formed at a relatively lower temperature.
It is not always necessary to form pure chromium (III) hydroxide or chromium (III) phosphate layer on the substrate. Not only a mixture of the chromium (III) hydroxide and chromium (III) phosphate, but also another mixture, preferably the mixture which contains colorless metal oxides, can be used. If such is the case, the colorless metal oxides are deposited in a form of a film layer together with the insoluble chromium (III) compounds, or they are deposited before or after the insoluble chromium (III) compounds are deposited.
The thus precipitated chromium (III) hydroxide or chromium (III) phosphate layer can be converted to its chemical composition by a subsequent reaction. For instance, the precipitated chromium (III) hydroxide layer can be converted to the chromium (III) phosphate layer partially or entirely by treating the substrate particles coated with the chromium (III) hydroxide layer with a solution which contains phosphate, and this can be done without impairing the advantageous effect of the precipitated chromium (III) hydroxide layer.
In order to achieve the weather resistance improvement in accordance with the present production process, it is sufficient to coat the substrate with the insoluble chromium (III) compounds in a relatively small amount. For instance, a satisfactory stabilizing effect can be already appreciated in a coating amount of 0.5% by weight (a value calculated as a CrCl 3 weight with respect to a total weight of the substrate). The present inventors have found that, after it is calcined, the novel pigment produces a more beautiful gold color hue as the insoluble chromium (III) compounds coating amount increases. This phenomenon results from the generation of chromium titanate. However, when the substrate is coated with the insoluble chromium (III) compounds in an amount of approximately 4% by weight or more, the whole chromium cannot be converted into the chromium titanate, part of the chromium is left as chromium oxides, and eventually the chromium oxides themselves appear in green as a powder color of the substrate. This coloring is not preferable in general, though it can be used for a special usage. Therefore, it is preferred to coat the substrate with the insoluble chromium (III) compounds in an amount of from 0.2 to 3% by weight approximately which is calculated as a Cr 2 O 3 weight with respect to a total weight of the substrate.
The weather resistance of the novel pigment cannot be improved satisfactorily by only carrying out the second coating step after the sputtering treatment. This is believed as follows. The conventional techniques are intended for a simple one-component layer which includes the TiO 2 of the rutile type or the like, and they are not intended for a complex three-component layer which includes the TiO 2 , low order oxides of titanium and metallic titanium. Hence, it is hard to coat a uniform chromium (III) hydroxide layer on an entire surface of this three-component layer by carrying out the coating treatment once, and accordingly there remain parts on which the treatment is applied insufficiently. Thus, the weather resistance cannot be improved.
In addition, when only the first coating step before the sputtering treatment is carried out, parts of the chromium (III) hydroxide layer are destroyed by the titanium plasma in a high energy state during the sputtering. As a result, it is also believed that no sufficient weather resistance can be given to the novel pigment.
On the other hand, when the first and second coating steps are carried out, the parts of the chromium (III) hydroxide layer, which have been destroyed by the titanium plasma in a high energy state during the sputtering, are coated with the chromium (III) hydroxide again, and most of the base (i.e., the TiO 2 layer) has been already coated with the chromium (III) hydroxide layer. Consequently, it is believed that the chromium (III) hydroxide layer are coated efficiently on the low order oxides of titanium and the metallic titanium which are formed in a scattering manner.
The novel pigment produced in accordance with the present process has a remarkably improved weather resistance when compared with the pigments produced by the conventional techniques. This novel pigment can be used in the same usages as the current usages, for instance, it can be used as an additive for plastics, inks, paints or the like, and it can be used in cosmetics as well. The improved weather resistance enables the present novel pigment to be used in any application in which it is subjected to a variety of environmental conditions, for example, it is optimum for automobile paints.
BRIEF DESCRIPTION OF THE DRAWINGS
A more complete appreciation of the present invention and many of its advantages will be readily obtained as the same becomes better understood by reference to the following detailed description when considered in connection with the accompanying drawings and detailed specification, all of which forms a part of the disclosure:
FIG. 1 is a schematic cross sectional view of a pigment of a First Preferred Embodiment according to the present invention;
FIG. 2 is an enlarge schematic cross sectional view of the pigment of the First Preferred Embodiment for explaining optical operations thereof;
FIG. 3 is a front view of a powder sputtering apparatus which is employed for producing the pigment of the First Preferred Embodiment;
FIG. 4 is a side view of the powder sputtering apparatus;
FIG. 5 is an Auger electron spectroscopy (hereinafter simply referred to as "AES") chart of the pigment of the First Preferred Embodiment;
FIG. 6 is an X-ray diffraction chart of the pigment of the First Preferred Embodiment;
FIG. 7 is a scanning electron microscope (hereinafter simply referred to as "SEM") photograph for illustrating a particulate structure of the pigment of the First Preferred Embodiment;
FIG. 8 is an AES chart of a pigment of a Second Preferred Embodiment according to the present invention;
FIG. 9 is a schematic cross sectional view of a pigment of a Fifth Preferred Embodiment according to the present invention; and
FIG. 10 is an enlarged schematic cross sectional view of the pigment of the Fifth Preferred Embodiment for explaining optical operations thereof;
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Having generally described the present invention, a further understanding can be obtained by reference to the specific preferred embodiments which are provided herein for purposes of illustration only and are not intended to limit the scope of the appended claims.
FIRST PREFERRED EMBODIMENT
FIGS. 1 and 2 are schematic cross sectional views of the pigment of the First Preferred Embodiment according to the present invention. This pigment comprises a mica 100 as the scaly substrate, a TiO 2 layer 101 coated on an entire surface of the mica 100, light absorbing portions 102 formed on a surface of the TiO 2 layer 101 in a scattering manner and including low order oxides of titanium, and glossy portions 103 formed on a surface of the light absorbing portions 102 in a scattering manner and including metallic titanium. A production process for this pigment will be hereinafter described.
Production of Pearl Mica Pigment
50 grams of a mica flake which had a particle diameter of from 10 to 20 micrometers and a thickness of 0.5 micrometers approximately were added to 500 milliliters of ion-exchanged water, and it was stirred to disperse uniformly. 158.2 milliliters of an aqueous titanyl sulfate which had a concentration of 40% by weight was added to the resulting dispersion. Then, the dispersion was boiled for 6 hours while stirring. After cooling the dispersion, the resulting precipitates were filtered and washed, and they were calcined at a temperature of 900° C. Thus, a red pearl mica pigment whose surface was covered with TiO 2 was obtained in an amount of 90 grams.
Description on Power Sputtering Apparatus
Then, a metallic titanium sputtering was carried out onto the thus obtained pearl mica pigment by using the powder sputtering apparatus illustrated in FIGS. 3 and 4. This powder sputtering apparatus comprised a decompression and heating treatment chamber 1, a rotary barrel type sputtering chamber 2, a fluid jet mill 3, and a powder filter 4.
The decompression and heating treatment chamber 1 was a container which was heated with an electric resistance, and it communicated with a main exhaust system 6 and a higher degree exhaust system 7 by way of a filter 5. The main exhaust system 6 was a mechanical vacuum pump, and the higher degree exhaust system 7 was a combination of a cryosorption pump, a turbo molecular pump, a mechanical booster pump or the like and a refrigerating trap. The decompression and heating treatment chamber 1 included a screw feeder 9 and a motor 40 for rotating the screw feeder 9, and it was adapted so that decompressed and heated fine powders 8 were dropped into a conduit 10 which was provided for delivering the fine powders 8 into the rotary barrel type sputtering chamber 2.
The rotary barrel type sputtering chamber 2 (hereinafter simply referred to as "barrel" 2) was a rotatable cylindrical body which had a construction like a ball mill, as illustrated in FIG. 4. One of its side walls supported a shaft which also worked as the conduit 10 by way of a magnetic seal 30 rotatably, and the other one of its side walls supported a shaft 12 which worked as a rotary shaft by way of a magnetic seal 30 rotatably. At a front end of the shaft 12, a pair of sputtering apparatuses 50 were held opposedly, as illustrated in FIG. 3. The attitude of the sputtering apparatuses 50 was not vertical, but they had an inclination which depended on positions of a fluidized fine powder bed 18 resulting from the rotation of the barrel 2. These sputtering apparatuses 50 were operated by a high frequency electric current which were supplied through the shaft 12.
The sputtering apparatuses 50, for example, a bipolar magnetron, were held on an extension line of the shaft 12, and they were constructed so that their distances from the fluidized fine powder bed 18 were adjustable with a height adjustment screw (not shown). Of course, this height adjustment was carried out with the side walls of the barrel 2 removed when a sputtering operation was not under way.
As illustrated in FIG. 3, the conduit 10 communicated with the decompression and heating treatment chamber 1 by way of a valve 121. Turning now to FIG. 4, the conduit 10 entered into the barrel 2 horizontally through the one of the side walls of the barrel 2, and it curved downward again to reach near a bottom of the barrel 2. The conduit 10 did not curve downward vertically, but it curved so as to face the positions of the fluidized fine powder bed 18 which resulted from the rotation of the barrel 2. Further, as illustrated in FIG. 3, the conduit 10 included a pipe 19 therein which communicated with the main evacuation system 6 and the higher degree evacuation system 7 and an inert gas supply source 31. Furthermore, the conduit 10 communicated with an exhaust conduit 11 by way of a valve 122. The exhaust conduit 11 was adapted for delivering the fine powders to the fluid jet mill 3.
Moreover, pipes which were made of graphite and which were less likely to be coated by sputtering were used for the conduit 10, which were disposed in the barrel 2, and the exhaust conduit 11 as well as for the smaller diameter pipe 19, which communicated with the main evacuation system 6 and the like.
The barrel 2 was supported by a pair of supporting rollers 13. One of the supporting rollers 13 was connected to a rotary shaft of a motor 14 by way of a belt 15. Thus, the barrel 2 was rotated by the rotation of the motor 14.
The fluid jet mill 3 included a propeller 21 which was rotated by a motor 20 so that the fine powders delivered through the exhaust conduit 11 collided with the propeller 21. An exhaust side of the fluid jet mill 3 communicated with a circulation pipe 23 which included a valve 22, and the circulation pipe 23 further communicated with the decompression and heating treatment chamber 1. Furthermore, a lower side of the valve 22 of the circulation pipe 23 communicated with the powder filter 4 which included a valve 24. The powder filter 4 was a trap which communicated with an exhaust system 26 by way of a cylindrical filter 25.
Formation of Light Absorbing Portions and Metallic Glossy Portions
90 grams of the above-described pearl mica pigment was supplied into the barrel 2 of the above-described powder sputtering apparatus, and the decompression and heating treatment chamber 1 was decompressed to 2×10 -5 Torr. Then, an argon gas was supplied gradually through a pipe 31 in order to supply the pigment into the fluid jet mill 3. After colliding the pigment with the propeller 2 so as to disperse it in its primary particles, the pigment was collected in the decompression and heating treatment chamber 1. Then, the decompression and heating treatment chamber 1 was decompressed to 2×10 -2 Torr, and it was heated to 100° C. with a heater. Thus, the collected pigment was dried, and degassing was carried out for 30 minutes.
Thereafter, the pigment was transferred into the barrel 2 whose atmosphere had been substituted with an argon gas in advance. Then, sputtering was started with a bipolar type magnetron under a decompression of 2×10 -2 Torr while rotating the barrel 2 at a speed of 5 rpm. The sputtering conditions were as follows: A target was titanium. Two power sources each having a capacity 0.2 kW were used. A frequency was 13.56 MHz. A temperature of the pigment was 200° C. or less. When the sputtering was carried out under these conditions for 1 hour, the pigment was coated with titanium in an amount of approximately 0.05% of the entire surface area of the pearl mica pigment (or 2.0% by weight with respect to the weight of the pearl mica pigment). This process was repeated 10 times to coat the pigment with titanium in an amount of 95% (or 20% by weight) in total.
After coating the pigment, an argon gas was supplied into the barrel 2 through the pipe 31 so as to collect the thus obtained pigment in the powder filter 4.
Evaluation
The thus obtained pigment was subjected to the AES analysis for its surface and to the X-ray diffraction analysis. The results of these analyses are illustrated in FIGS. 5 and 6. According to FIGS. 5 and 6, the pigment had the low order oxides of titanium on its surface, and of course it had the titanium layer formed thereon. Namely, it is apparent that the TiO 2 was reduced to form the low order oxides of titanium when the sputtered atoms including titanium collided with the TiO 2 layer.
In addition, when the thus obtained pigment was observed with an SEM, it was observed that the titanium particles were formed like islands in a scattering manner on its surface, as illustrated in FIG. 7.
SECOND PREFERRED EMBODIMENT
The pigment of the Second Preferred Embodiment was produced in an identical manner with that of the First Preferred Embodiment. However, the production process of this pigment differed in that the aqueous titanyl sulfate was used in an amount of 3125.5 milliliters to prepare a pearl mica pigment which produced the interference color in green in an amount of 100 grams in the production step of pearl mica pigment, and in that two power sources each having a capacity 3.0 kW were used in order to carry out sputtering so that the pearl mica pigment is coated with metallic titanium in an amount of approximately 3.0% by weight with respect to the weight of the pearl mica pigment for 1 hour. This process was repeated 10 times to coat the pearl mica pigment with metallic titanium in an amount of 30% by weight in total, thereby obtaining the pigment of the Second Preferred Embodiment in green.
According to the AES analysis for the thus obtained green pigment, it was found that the surface of the mica was coated with a film layer of low order oxides of titanium in a thickness of 0.66 micrometers approximately. The component ratio of titanium with respect to oxygen varied in the thickness-wise direction of the TiO 2 layer of the pigment, as illustrated in the AES chart of FIG. 8.
THIRD PREFERRED EMBODIMENT
Preparation of Paint
The pigment obtained in the First Preferred Embodiment was mixed with an acryl melamine clear paint so that a "PWC" (i.e., pigment weight content) was 10%. The acryl melamine clear paint included an acrylic resin in an amount of 35% by weight, a butylated melamine resin in an amount of 15% by weight, an organic solvent in an amount of 5% by weight, and additives in trace amounts. The resulting mixture was stirred to uniformize it sufficiently. A metallic paint of the Third Preferred Embodiment was thus prepared.
Evaluation on Paint
This metallic paint was coated on a black and white covering power test paper with a 25-mil bar coater, and then it was baked and dried at 140° C. for 30 minutes to form a paint film. The paint film was measured for each of the hues on the black base surface and the white base surface, and it was also evaluated visually for the overall coverability, the color turbidity (or the transparency), the metallic glossy effect and the ability to vary the hue depending on viewing angles (i.e., the "flip-flop" characteristic). The results of these tests are summarized in Table 1. It is apparent from Table 1 that this paint film produced strong interference colors, that it had a good metallic glossy effect, and that it was superior in the coverability.
It is apparent from the following facts that this pigment had a construction as schematically shown in FIG. 1. Namely, it was necessary that the TiO 2 layer be exposed partially at least in order to produce the interference colors. The low order oxides of titanium were formed when the titanium collided with the TiO 2 layer. The pigment had a metallic glossy effect resulting from titanium. The surface of the pigment was observed with an SEM to have the titanium particles formed in a scattering manner.
FOURTH PREFERRED EMBODIMENT
A metallic paint of a Fourth Preferred Embodiment was prepared in an identical manner with that of the Third Preferred Embodiment other than that a pigment which was coated with titanium by the sputtering in an amount of 2.0% by weight was used. This metallic paint was evaluated similarly, and the results of the tests are also summarized in Table 1. The paint film produced an intermediate color between white, which was similar to an aluminum metallic effect, and silver.
COMPARATIVE EXAMPLE 1
A metallic paint of a Comparative Example 1 was prepared in an identical manner with that of the Third Preferred Embodiment other than that the pearl mica pigment which was not subjected to the sputtering was used. This metallic paint was evaluated similarly, and the results of the tests are also summarized in Table 1.
COMPARATIVE EXAMPLE 2
A metallic paint of a Comparative Example 2 was prepared in an identical manner with that of the Third Preferred Embodiment other than that a pearl mica pigment on which silver was deposited in a scattering manner by electroless plating was used instead of the pigment of the First Preferred Embodiment. The thus deposited silver occupied 95% of the entire surface area of the TiO 2 layer in a projection area in total. This metallic paint was evaluated similarly, and the results of the tests are also summarized in Table 1.
TABLE 1______________________________________ 3rd Pref. 4th Pref. Comp. Comp. Embodiment Embodiment Ex. 1 Ex. 2______________________________________Titanium 20 2.0 0 Silver(% byweightWhite L* 29.61 38.62 84.80 46.33Base a* 2.66 9.36 -0.20 -0.85 b* 0.25 0.65 6.46 -6.02Black L* 29.36 33.82 46.31 46.07Base a* 2.69 13.63 18.34 -1.14 b* 0.15 -1.94 -2.51 -6.19Coverability good good to fair bad fairTransparency good good good goodMetallic good good to fair bad goodGlossy EffectFlip-Flop good good to fair fair to bad goodCharacteristic______________________________________
Table 1 tells us that the metallic paints of the Third and Fourth Preferred Embodiments were superior to those of Comparative Examples 1 and 2 in the covering power, and that they had strong interference colors. It is apparent that these advantages were effected by forming the light absorbing portions and the metallic glossy portions on the surface of the TiO 2 layer of the pearl mica pigment in a scattering manner.
FIFTH PREFERRED EMBODIMENT
FIGS. 9 and 10 are schematic cross sectional views of the pigment of the Fifth Preferred Embodiment according to the present invention. This pigment comprises a mica particle 100, a TiO 2 layer 101 coated on a surface of the mica particle 100, a chromium (III) hydroxide layer 104 formed on a surface of the TiO 2 layer 101, light absorbing portions 102 formed further on a surface of the TiO 2 layer 101 in a scattering manner and including low order oxides of titanium, glossy portions 103 formed on a surface of the light absorbing portions 102 and including metallic titanium, and a chromium (III) hydroxide layer 105 formed further on surfaces of the TiO 2 layer 101, the chromium (III) hydroxide layer 104 and glossy portions 103. The TiO 2 layer 101, the light absorbing portions 102 and the glossy portions 103 operate optically identically with those of the pigment of the First Preferred Embodiment. Hence, their operations will not be described herein. The chromium (III) hydroxide layers 104 and 105 which are present on the surface of the TiO 2 layer and the outermost surface of this pigment do not give a decorative effect optically. However, the chromium (III) hydroxide layers 104 and 105 improve the weather resistance of this pigment remarkably because they are present in the two-layered construction.
A production process for the pigment will be hereinafter described.
First Coating Step
90 grams of the same red pearl mica pigment which was obtained in the production step of pearl mica pigment in the First Preferred Embodiment was made into a slurry with 1,500 milliliters of distilled water. A pH of the slurry was adjusted to 6.0 by dripping a 2N sulfuric acid. Then, 116 milliliters of a 5% chromium chloride (CrCl 3 ) solution was diluted with 360 milliliters of distilled water, and this diluted solution was added to the above-described slurry at a constant rate for 30 minutes approximately. While adding this diluted chromium chloride (CrCl 3 ) solution to the slurry, the pH of the slurry was always kept at 6.0 by adding a 10% potassium hydroxide solution in required amounts.
After adding all of the diluted chromium chloride (CrCl 3 ) solution, the slurry was filtered and washed. The resulting precipitates were dried at a temperature of from 110° to 120° C. for 1 hour. Thus, the pearl mica pigment was coated with a chromium (III) hydroxide thin film in an amount of 4% by weight.
Formation of Light Absorbing Portions and Metallic Glossy Portions
93.6 grams of thus coated pearl mica pigment was subjected to the sputtering operation under the same conditions as set forth in the First Preferred Embodiment. Namely, when this step was completed, the pigment was coated with titanium in an amount of 20% by weight in total with respect to the weight of the pearl mica pigment.
Second Coating Step
117 grams of the thus obtained pigment was made into a slurry with 2,000 milliliters of distilled water. A pH of the slurry was adjusted to 6.0 by dripping a 2N sulfuric acid. Then, 151 milliliters of a 5% chromium chloride (CrCl 3 ) solution was diluted with 468 milliliters of distilled water, and this diluted solution was added to the above-described slurry at a constant rate for 30 minutes approximately. While adding this diluted chromium chloride (CrCl 3 ) solution to the slurry, the pH of the slurry was always kept at 6.0 by adding a 10% potassium hydroxide solution in required amounts.
After adding all of the diluted chromium chloride (CrCl 3 ) solution, the slurry was filtered and washed. The resulting precipitates were dried at a temperature of from 110° to 120° C. for 1 hour. Thus, the resulting pigment was further coated with a chromium (III) hydroxide thin film in an amount of 4% by weight. The thus obtained pigment produced an intermediate color between metallic grayish white and red.
The thus produced pigment was made into a metallic paint in the same manner as set forth in the Third Preferred Embodiment. This metallic paint was coated and made into a paint film in an identical manner with that of the Third Preferred Embodiment other than that it was coated on a test panel which was made of steel and which was undercoated with an epoxy resin paint in a thickness of 5 micrometers instead of the black and white covering power test paper used in the Third Preferred Embodiment.
Then, a QUV test was carried out onto the paint film for 1,000 hours. The results of the test are summarized in Table 2. In Table 2, the components amounts of the thin films were their respective calculated values in the pigments which had undergone their respective final treatments.
The 1,000-hour QUV test was conducted with a QUV testing apparatus. The QUV testing apparatus was operated at a temperature of 65° C. approximately with its ultraviolet lamps turned on for a 4-hour cycle, and then it was operated at a temperature of 50° C. approximately with its ultraviolet lamps turned off under a water or moisture condensing condition for a 4-hour cycle. These 2 cycles were repeated 3 times in 24 hours. Hence, the test panel coated with the metallic paint was exposed to a pseudo-high-temperature tropical day-time condition followed by a warm and high-moisture night-time condition. During the exposure, the moisture or water condensed on the test panel surface. When the test panel was wetted by the condensed moisture or water, the test panel was exposed to a ultraviolet light which intensifies as the cycles, during which the ultraviolet lamps turned on, were carried out repeatedly. Thus, the QUV test is based on the fact that the most of the polymer materials in the paint film, which are coated on the steel test panel, are adversely affected considerably when the influences of the high temperature, the high humidity and the ultraviolet irradiation are combined.
A plurality of the test panels which were coated with an identical metallic paint were placed in this QUV testing apparatus, and the test panels were taken out of the QUV testing apparatus one by one periodically to evaluate their appearance variations with a color difference meter and a glossimeter. The color differences between before and after the QUV test and the glossiness differences therebetween were taken as a color difference (ΔE) and a glossiness holdability (%) respectively, and they are summarized in Table 2.
TABLE 2__________________________________________________________________________ 5th Pref. 6th Pref. Comp. Comp. Comp. Embodiment Embodiment Ex. 3 Ex. 4 Ex. 5__________________________________________________________________________Components of TiO.sub.2 34.2 43.1 36.8 35.3 35.3Tin Films 1st Cr(OH).sub.3 3.1 0.5 0 0 4.1(% by weight) Coating Low Order 6.7 2.2 4.6 4.4 4.4 Oxides of Ti by Sputtering Metallic Ti 14.7 0.5 12.6 12.1 12.1 by Sputtering 2nd Cr(OH).sub.3 4.0 0.5 0 4.1 0 CoatingAfter 1,000- Discoloration 0.2 0.3 5.8 3.6 2.1hr. QUV Test (Color Difference) Glossiness 91 88 20 35 50 (Holdability in %)__________________________________________________________________________
SIXTH PREFERRED EMBODIMENT
A pigment of a Sixth Preferred Embodiment was prepared and made into a metallic paint in an identical manner with that of the Fifth Preferred Embodiment other than that the pigment was coated with titanium by the sputtering in an amount of 2.0% by weight and that the pigment was coated with the Cr(OH) 3 layer in an amount of 0.5% by weight in each of the first and second coating steps. This metallic paint was evaluated similarly, and the results of the tests are also summarized in Table 2. The paint film produced an intermediate color between red, which was similar to an aluminum metallic effect, and silver.
COMPARATIVE EXAMPLE 3
A pigment of a Comparative Example 3 was prepared and made into a metallic paint in an identical manner with that of the Fifth Preferred Embodiment other than that no Cr(OH) 3 layers were formed in both of the first and second coating steps. This metallic paint was evaluated similarly, and the results of the tests are also summarized in Table 2.
COMPARATIVE EXAMPLE 4
A pigment of a Comparative Example 4 was prepared and made into a metallic paint in an identical manner with that of the Fifth Preferred Embodiment other than that no Cr(OH) 3 layer was formed in the first coating step. This metallic paint was evaluated similarly, and the results of the tests are also summarized in Table 2.
COMPARATIVE EXAMPLE 4
A pigment of a Comparative Example 4 was prepared and made into a metallic paint in an identical manner with that of the Fifth Preferred Embodiment other than that no Cr(OH) 3 layer was formed in the second coating step. This metallic paint was evaluated similarly, and the results of the tests are also summarized in Table 2.
Table 2 tells us that, even after the 1000-hour QUV test, discoloration and decreased glossiness were hardly recognized in the test panels which were coated with the metallic paints comprising the pigments onto which the chromium (III) hydroxide treatments of the first and second coating steps were carried out repeatedly as set forth in the Fifth and Sixth Preferred Embodiments. Hence, it is apparent that these test panels exhibited superior weather resistances.
On the other hand, after the 1,000-hour QUV test, discoloration occurred considerably and the glossiness decreased sharply in the test panel which were coated with the metallic paint comprising the pigment of the Comparative Example 3 onto which no chromium (III) hydroxide treatments of the first and second coating steps were carried out, and in the test panel which were coated with the metallic paint comprising the pigment of Comparative Example 4 onto which only the chromium (III) hydroxide treatment of the second coating step was carried out, and in the test panel which were coated with the metallic paint comprising the pigment of the Comparative Example 5 onto which only the chromium (III) hydroxide treatment of the first coating step was carried out. In particular, degradation occurred extremely considerably in the test panel which were coated with the metallic paint comprising the pigment of the Comparative Example 3 onto which no chromium (III) hydroxide treatments were carried out. When comparing the degradations exhibited by the test panels coated with metallic paints comprising the pigments of the Comparative Examples 4 and 5, it is apparent that the first coating step contributed slightly more to the weather resistance improvement than the second coating step did.
Having now fully described the present invention, it will be apparent to one of ordinary skill in the art that many changes and modifications can be made thereto without departing from the spirit or scope of the present invention as set forth herein including the appended claims. | Disclosed are a pigment, a production process therefor, a production process therefor and for improving its weather resistance, and a metallic paint made therefrom. The pigment includes a transparent or semi-transparent scaly substrate, a TiO 2 layer coated on an entire surface of the substrate, light absorbing portions formed on a surface of the TiO 2 layer in a scattering manner and including low order oxides of titanium, and glossy portions formed on a surface of the TiO 2 layer in a scattering manner and having a metallic glossy effect. The pigment produces a metallic glossy effect resulting from the glossy portions, strong interference colors resulting from the TiO 2 layer and substance colors resulting from the light absorbing portions, and it exhibits a great covering power. Such an excellent pigment can be obtained by the production process in which sputtering is carried out onto a conventional pearl mica pigment, and its weather resistance can be improved by the production process in which chromium (III) hydroxide is repeatedly coated on a conventional pearl mica pigment before and after the sputtering. When the metallic paint is made from the pigment, it naturally has the metallic glossy effect, the strong interference colors, the substance colors and the great covering power all of which result from the pigment and is suitable for an automobile top coat paint. | 2 |
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] Embodiments of the present invention generally relate to tools and tool storage and display mechanisms. The invention more particularly relates to tampers or tamping tools. Still further, the invention pertains to a tamper or tamping tool that includes a pivoting handle assembly configured to pivot between various orientations relative to a tamping base.
[0003] 2. Description of the Related Art
[0004] In the tool industry, it is desirable to display tools in an organized and presentable manner while conserving space in a retail environment. In addition, it is desirable for the consumer to be able to transfer and store a tool with less space requirements. One way in which, this can be achieved is through the incorporation of a pivotal or foldable handle on the tool.
[0005] Folding handle mechanisms for particular tools are readily known within the art. For instance, camping or “army” shovels generally incorporate a spade on a shank or handle, wherein the spade is adjoined to the handle by a pivoting mechanism. In general, the pivoting mechanism is located at the business end or head of the spade, thereby allowing the spade to be pivotally fixed in a variety of orientations relative to the handle. The pivoting mechanism typically incorporates a collar threaded on to the handle that is tightened against one of a plurality of planar surfaces within the pivoting mechanism. Each planar surface is configured to rigidly orient the spade in a particular direction by allowing the shank to securely tighten against the surface. In order to change the orientation of the spade, the collar is loosened from the planar surface until the distance required for the collar to clear the planar surface is achieved, thereby allowing the handle to pivot away from the surface. The handle can then be pivoted to another direction, wherein a planar surface is configured to secure the handle in that particular direction.
[0006] FIG. 1 provides a schematic view of an exemplary tamper or tamping tool 10 well known by a person of ordinary skill in the art. A tamper is generally used for packing or compressing material, such as clay, sand, or dirt, by a sequence of strikes. For instance, a tamper can be used to compress stone dust or sand, in order to form a solid foundation for walkways or patios made from brick or stone. It is also common practice to tamp clay, sand, or dirt into a drill hole above an explosive device to effectively direct the force of the explosion. A tamper can also be used to simply tamp a section of earth or loose soil to create a smooth area. Typically the tamper 10 includes a square tamping base 12 with the dimensions of 8 inches by 8, inches or 10 inches by 10 inches along the edge of the base 12 . The base 12 is fixably attached to an elongated handle or shank 11 . The handle 11 and base 12 are affixed at a juncture 14 disposed at the center of the base 12 on an upper portion thereof. The handle 11 includes a gripping surface 15 disposed at an end of the handle 11 opposite to the base 12 . The gripping surface 15 allows the user to ergonomically operate the tamper 10 by providing a non-slip surface for the user to manually elevate and lower the tamper 10 onto the desired surface. The soil or dirt is compressed by lowering the bottom surface 13 of the base 12 onto the soil or dirt and applying a downward force. The base 12 is generally manufactured as one piece from steel or iron to allow a significant amount of force to be applied to the surface desired for tamping. The handle 11 can be constructed from iron, steel, fiberglass, wood, or hardened plastic so long as the handle 11 can resist the force imparted on the surface by the base 12 .
[0007] As shown in FIG. 1 , the tamper 10 does not include a pivoting mechanism or a foldable handle. The bottom surface 13 of the tamping base 12 is, as shown, substantially normal to the longitudinal axis of the handle. Furthermore, since the handle 11 is disposed on a center portion of the tamping base 12 , the base 12 occupies a significant amount of space being that the base 12 protrudes axially in all directions from the handle 11 . Therefore, a need exists for a tamper having a foldable or pivotal handle for substantially reducing the area occupied by the tamper during transportation, display, and storage of the tamper. Further, there is a need for a tamper having a foldable or pivotal handle that has the structural integrity to shoulder the amount of force required during a tamping operation.
SUMMARY OF THE INVENTION
[0008] The present invention provides apparatus and methods for pivoting a handle on a tamper tool between a plurality of positions. In one embodiment of the present invention, a tamper tool assembly first includes a pivoting handle assembly. The tamper tool assembly includes an elongated handle having a collar attached to a distal end, a tamping base having an upper surface and a lower surface, and a housing member disposed on the upper surface of the tamping base. The housing member includes a plurality of clamping surfaces and a joint configured to pivotally receive the elongated handle.
[0009] A method of pivoting a handle on a tamper tool assembly having a tamping base according to one embodiment of the present invention is also provided. The handle is pivoted on the tamper tool by first providing a housing member on an upper surface of the tamping base, wherein the housing member includes a plurality of clamping surfaces and a joint configured to pivotally receive the elongated handle. A collar is provided on a threaded portion of the handle, wherein the collar is frictionally engaged to a first clamping surface. The collar is then loosened along the threaded portion of the handle, thereby disengaging the collar from the first clamping surface. The handle is then pivoted into alignment with a second clamping surface and then the collar is tightened along the treaded portion into frictional engagement with the second clamping surface.
BRIEF DESCRIPTION OF THE DRAWINGS
[0010] So that the manner in which the above recited features of the present invention can be understood in detail, a more particular description of the invention, briefly summarized above, may be had by reference to embodiments, some of 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.
[0011] FIG. 2 presents an elevational side view of a tamper tool according to one embodiment of the present invention.
[0012] FIG. 3 shows a perspective view of the tamper according to one embodiment of the invention.
[0013] FIG. 4 provides a sectional side view of the tamper according to the embodiment of the present invention illustrated in FIG. 3 .
[0014] FIG. 5 provides a schematic view of a topside of the tamping tool according to an embodiment of the present invention.
[0015] FIG. 6 provides a perspective view of the tamping tool according to one embodiment of the present invention.
[0016] FIG. 7 is a sectional view of a topside of the tamping tool as illustrated in FIG. 6 .
[0017] FIG. 8 provides a cross-sectional side view of a tamper having a handle assembly with a two-part construction according to one embodiment of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0018] Embodiments of the present invention generally relate to an apparatus and method for providing a folding or pivoting handle assembly for a tamper or tamping tool. Particularly, embodiments of the present invention relate to tamper that includes a folding design, thereby allowing a tamping base to be securely and firmly oriented in a plurality of orientations.
[0019] FIG. 2 presents an elevational side view of a tamper tool 20 according to one embodiment of the present invention. The tamper tool shown in FIG. 2 includes a tamping base 22 and a handle assembly or elongated shank 21 . The tamping base 22 includes a planar portion 23 disposed at a bottom portion. The planar surface 23 is shown as a rectangular shape; however, it is understood that other shapes such as a circular or amorphous shape can be used to define the planar surface 23 on the base 22 . A tamping base 22 with straight edges, such as in FIG. 2 , is advantageous for tamping an area with a defined border. The tamping base 22 also includes a centrally disposed housing member 33 . The housing member 33 serves to receive the distal end of the handle assembly 21 , which will be discussed in further detail below. As shown in FIG. 2 , the tamping base 22 also includes a plurality of reinforcement members 32 disposed between the tamping base 22 and the housing member 33 . The reinforcement members 32 consist of a planar coupling or gusset that forms a substantially right angle between the housing member 33 and a topside ( 24 in FIG. 3 ) of the tamping base 22 .
[0020] As shown in FIG. 2 , the handle assembly 21 includes an engagement means 26 , such as a collar, disposed at a distal end adjacent to the tamping base 22 . The collar 26 can be adjoined to the handle assembly 21 by any means well known within the art, such as by a threaded means ( 35 in FIG. 3 ). In one embodiment of the present invention, the threaded portion 35 of the handle may be an integral part of the handle assembly 21 . In another embodiment of the present invention, the handle assembly 21 has a two-part construction, wherein the threaded portion 35 is manufactured out of a different material than the remaining portion of the handle assembly 21 . For instance, the threaded portion 35 of the handle assembly 21 can be manufactured from aluminum or steel, while the remaining portion of the handle assembly 21 is constructed out of lighter material, such as wood or fiberglass. The embodiment of the present invention having a two-part handle assembly 21 construction will be discussed in further detail with regard to FIG. 8 . Referring again to FIG. 2 , a plurality of male coupling members 27 is disposed around the collar 26 . The male coupling members 27 , as shown in FIG. 2 , are disposed substantially equidistant from each other. The handle assembly 21 also includes a gripping member 25 disposed at a proximal end. The gripping member 25 is designed to provide a non-slip surface for the user to elevate and lower the tamper 20 during operation.
[0021] FIG. 3 shows a perspective view of the tamper 20 according to one embodiment of the invention. As shown in FIG. 3 , the housing member 33 is open at a top portion and a side portion. These openings allow the handle assembly to pivot downward in the direction of the open side portion until contacting the topside 24 of the tamping base 22 . In this perspective, a threaded portion 35 of the handle assembly 21 is shown disposed within the housing member 33 . In one embodiment, the handle assembly 21 is pivotally adjoined to the housing member 33 and thereby to the tamping base 22 by a bolt 29 . The pivot bolt 29 is disposed through the housing member 33 and through the distal end of the handle assembly 21 and is secured onto the two opposing sides of the housing member 33 . In another embodiment, a pivot bolt 29 is disposed through an angled slot incorporated into the distal end of the handle assembly 21 . This embodiment will be described in further detail below. However, it is understood that any pivoting means, such as a pin, known to a person of ordinary skill in the art can be used to effectively pivot the handle assembly.
[0022] Referring again to FIG. 3 , the housing member 33 also includes a primary and a secondary clamping surface, 40 and 41 , respectively, designed to abut a lower planar surface of the collar 26 . The primary clamping surface 40 includes the planar edges of the open top portion of the housing member 33 . As shown in FIG. 3 , the collar 26 is in an engaged position with the primary clamping surface 40 , wherein the collar 26 is tightened against the primary clamping surface 40 thereby preventing the handle assembly 21 from pivoting downward. However, it is understood that the threaded collar 26 is only one way of clamping the handle 21 to the tamping base 22 and other engagement means known to a person of ordinary skill in the art, such as “over-center” cams or cams in conjunction with a threaded means, can be employed. Having been clamped against the primary surface 40 , the handle assembly 21 is oriented in a substantially perpendicular relationship to the tamping base 22 . This orientation allows the user to effectively operate the tamping tool 20 by elevating the tool 20 and pushing the tool 20 downward against the surface desired for tamping. The secondary clamping surface 41 includes the planar edges of the open side portion of the housing member 33 protruding from the top portion 24 of the tamping base 22 . Once the collar 26 is loosened from the primary clamping surface 40 the handle assembly 21 can pivot downward and the collar 26 can then be tightened against the secondary clamping surface 41 . The tamping tool 20 with respect to this position will be described in further detail below. An intermediate arcuate profile 28 is disposed on an upper portion of the housing member 33 between the primary and secondary clamping surfaces 40 , 41 . The arcuate profile 28 facilitates the pivoting of the handle assembly between the clamping surfaces 40 , 41 while maintaining a substantially planar surface on the clamping surfaces 40 , 41 by reducing the length that the collar 25 needs to be loosened in order to pivot.
[0023] FIG. 4 provides a sectional side view of the tamper 20 according to the embodiment of the present invention illustrated in FIG. 3 . The handle assembly 21 is oriented in a vertical position and is tightened against the primary clamping surface 40 of the housing member 33 . In this operational position, the longitudinal axis of the handle assembly 21 is oriented substantially perpendicular to the planar tamping or working surface 23 of the tamping base 22 . As shown in FIG. 4 , the distal end of the handle assembly 21 has a threaded portion 35 for receiving the collar 26 , which has a threaded inner surface (not shown) configured to mate with the threaded portion 35 of the handle assembly 21 . In one embodiment of the present invention, the handle assembly 21 also includes a washer assembly 30 disposed between the bottom of the collar 26 and the housing member 33 . As shown in FIG. 4 , the washer assembly 30 includes a Teflon washer 53 disposed between two stainless steel washers 51 , 52 . Teflon is advantageous due to its very low coefficient of friction. In particular when sliding against a polished, stainless steel surface, Teflon experiences a very small amount of friction. Stainless steel washers are preferable due to their resistance to corrosion, thereby maintaining a low coefficient of friction. The stainless steel washers can be effectively replaced by washers that also resist corrosion, such as heat-treated steel washers, coated or plated steel washers, or brass washers. In one embodiment, the Teflon washer can be any polymer having a good impact resistance and a low coefficient of friction, such as nylon. Although the Teflon washer 53 decreases the friction undergone by the washer assembly 30 , the Teflon washer 53 is not an essential component of the washer assembly 30 . In one embodiment, only the steel washers 51 , 52 are included in the washer assembly 30 to reduce the friction created between the collar 26 and the particular clamping surface, 40 or 41 .
[0024] The washer assembly 30 serves to minimize the friction between the collar 26 and the clamping surfaces 40 , 41 . This reduction in friction will allow a given amount of torque placed on the threaded collar to result in a greater separation force between the collar 33 and the clamping surfaces 40 , 41 . As the separation force is increased, the rigidity of the engagement between the handle assembly 21 and the clamping surface 40 , 41 will increase, thereby minimizing wear resulting from the impact of loading and thus increasing the overall life of the tamping tool 20 . In another embodiment of the present invention, the washer assembly 30 includes a roller thrust bearing (not shown) instead of the Teflon washer 53 and the steel washers 51 , 52 . The roller thrust bearing will also minimize the frictional forces between the collar 26 and the clamping surfaces 40 , 41 , thereby maximizing the joint rigidity.
[0025] FIG. 5 provides a schematic view of a topside of the tamping tool 20 according to an embodiment of the present invention. As shown in FIG. 5 , the tamping base 22 has a substantially square profile and the handle assembly 21 is substantially centrally disposed on the tamping base 22 within the housing member 33 . The handle assembly 21 being centrally disposed on the tamping base 22 functions to centrally balance the tamping base 22 while in an operational position, thereby stabilizing the tamping base 22 on the handle assembly 21 during operation. Each reinforcement member 32 extends from the housing member 33 along the vertical edge of the housing member 33 and along the upper surface 24 of the tamping base 22 until reaching a corner of the rectangular tamping base 22 profile. The reinforcement member 32 arrangement provides a substantial amount of support between the tamping base 22 and the housing member 33 while not adding a large amount of weight to the tamping base 22 . As shown in FIG. 5 , the washer assembly 30 protrudes radially from a lower portion of the collar 26 . The washer assembly 30 covers a significant portion of the primary clamping surface 40 .
[0026] FIG. 6 provides a perspective view of the tamping tool 20 according to one embodiment of the present invention. As shown in FIG. 6 , the handle assembly 21 has been pivoted into a “storage” or secondary position, wherein the collar 26 has been tightened against the secondary clamping surface 41 . In the secondary position, the longitudinal axis of the handle assembly is substantially parallel to the planar tamping surface 23 . This position allows the tamping tool 20 to be stored, transported, and displayed in a more efficient and space-saving manner by significantly reducing the amount in which the tool 20 extends axially with respect to the longitudinal axis of the handle assembly 21 . Referring again to FIG. 6 , the collar 26 has been loosened sufficiently from an engaged position with the primary clamping surface 40 ( FIG. 5 ) to allow the washer assembly 30 and the collar 26 to clear the arcuate intermediate portion 28 between the primary and secondary clamping surfaces 40 , 41 as the handle assembly 21 is pivoted from an “operational” position to a “storage” position.
[0027] FIG. 7 is a sectional view of a topside of the tamping tool 20 as illustrated in FIG. 6 . As shown in FIG. 6 , the washer assembly 30 is firmly tightened to the secondary clamping surface 41 . In one embodiment, the threaded portion 35 of the handle assembly 21 extends from adjacent to where the collar 26 is positioned in FIG. 7 to the tip of the distal end of the handle assembly 21 . This configuration of the threaded portion 35 improves the manufacturing process of the tool 20 by reducing the area that collar will slide on the handle assembly 21 before being threaded onto the handle assembly 21 when attached from the distal end of the handle assembly 21 . However, it is understood that only a small portion of the handle assembly 21 needs to be threaded so long as the collar 26 can be tightened and loosened along the threaded portion 35 sufficiently to pivot the handle assembly 21 into the desired orientation.
[0028] As previously described, the distal end of the handle assembly 21 can include an angled slot as opposed to a standard cylindrical hole for receiving the pivot bolt 29 , wherein the pivot bolt 29 is disposed through the angled slot and the sidewalls of the housing member 33 . The slot is angled such that when the collar 26 is tightened against the secondary clamping surface 41 , the slot will “cam” the handle against a sidewall of the housing member 33 . This added support provides a more rigid interface between the tamper base 22 and the handle assembly 21 .
[0029] FIG. 8 provides a cross-sectional side view of a tamper 20 having a handle assembly 21 with a two-part construction according to one embodiment of the present invention. As shown in FIG. 8 , the handle assembly 20 includes an upper member 55 and a lower member 56 . The upper member 55 includes a gripping portion (not shown) that allows the user to efficiently control the movement of the tamper 20 . The lower member 56 is attached to both the upper member 55 of the handle assembly 21 and to the collar 26 . As previously described, the lower member 56 can be manufactured from a different material than the upper member 55 . In one embodiment, the upper member 55 of the handle assembly 21 is manufactured from wood or fiberglass and the lower member 56 is manufactured from aluminum or steel.
[0030] This two-part construction allows the handle assembly 21 to be optimized for operation. Manufacturing the lower member 56 out of aluminum or steel allows threads to be adequately created on the handle assembly 21 while preserving the handle's 21 structural integrity. A wooden or fiberglass upper member 55 of the handle assembly 21 advantageously reduces or dampens the vibrations that reach the user's hand during normal operation of the tamping tool 20 . The upper member 55 can also be manufactured out of metal. Constructing the upper member 55 out of wood or fiberglass also greatly reduces the overall weight of the tamper 20 thereby allowing for easier operation by the user. However, it is understood that other materials well known in the art that can reduce vibrations in the handle assembly 21 can be used for the upper member 55 and other materials well known in the art that can maintain sufficient structural integrity when threaded can be used for the lower member 56 of the handle assembly 21 .
[0031] In one embodiment of the present invention, the lower member 56 of the handle assembly 21 is adjoined to the upper member 55 by an upper locking mechanism 57 and lower locking mechanism 58 , as shown in FIG. 8 . The locking mechanisms 57 , 58 serve to effectively lock the lower member 56 to the upper member 55 and to position the lower member 56 at the desired location on the handle assembly 21 . However, it is understood that any attachment means well known to person of ordinary skill in the art can be employed to adjoin the two members 55 , 56 of the handle assembly. For example, a fiberglass upper member 55 can be securely attached to the lower member 56 using an epoxy glue or resin. A shoulder portion 59 , which protrudes radially from the lower member 56 of the handle assembly 21 , prevents the upper member 56 from sliding too far down over the lower member 56 and serves to transmit the force imparted by the user on the upper member 55 of the handle assembly 21 to the lower member 56 , thereby transmitting force to the tamping base 22 . Force is also transmitted from the upper member 55 to the lower member 56 via the locking mechanism or attachment means used to adjoin the two members 55 , 56 .
[0032] While the foregoing is directed to embodiments of the present invention, other and further embodiments of the invention may be devised without departing from the basic scope thereof, and the scope thereof is determined by the claims that follow. | A tamper having a foldable or pivotal handle assembly for substantially reducing the area occupied by the tamper during transportation, display, and storage of the tamper is provided. The invention particularly pertains to a tamper tool assembly that includes a pivoting handle configured to pivot between various orientations relative to a tamping base. The tamper tool assembly includes an elongated handle assembly having a collar attached to a distal end, a tamping base having an upper surface and a lower surface, and a housing member disposed on the upper surface of the tamping base, wherein the housing member comprises a plurality of clamping surfaces and a joint configured to pivotally receive the elongated handle. | 4 |
FIELD OF THE INVENTION
The present invention is directed to a system for measuring the amount of crop material to be harvested by a harvesting machine. A scanning transmitter and receiver of electromagnetic radiation identifies the location and intensity of electromagnetic radiation reflected from the crop material located on a field and communicates that information to a controller that determines the amount of crop material to be harvested.
BACKGROUND OF THE INVENTION
Crop throughput sensors measuring the amount of crop processed by a harvesting machine are used to automatically control crop conveying and/or crop processing assemblies. Crop throughput is also frequently used for measuring the harvest in specific areas or sub-areas. The forward velocity of the harvesting machine can be controlled by a control arrangement in response to the measured crop throughput, such that a desired crop throughput is maintained corresponding to the optimum throughput of the harvesting machine. It is known to locate crop throughput sensors on a harvesting machine. In known systems, crop throughput measurements are performed after the crop has been harvested by the harvesting assembly of the harvesting machine. Because of the time delay between sensing crop throughput and its location in the harvesting machine, sudden changes in the crop throughput cannot be compensated by a corresponding change in forward velocity. As such, crop processing arrangements may become overloaded, underloaded, or jammed.
U.S. Pat. No. 4,228,636 proposes identifying the density of a standing crop on a field by using ultrasonic sensors mounted on a harvesting assembly. The sensors are arranged to sense standing crop located immediately in front of the cutter bar. A transmitter arranged on the side of the crop intake arrangement emits ultrasonic radiation that is propagated over the width of the crop intake arrangement. The loss of intensity of the ultra-sonic radiation as well as their propagation time detected by the receiver located opposite the transmitter and caused by the crop stand is evaluated and converted into a control signal. Due to external disturbance effects and error possibilities, ultra-sonic sensors have not been proven worthwhile in practical applications.
EP 0 887 660 A describes a harvesting machine that is equipped with a laser distance measuring arrangement. The laser distance measuring arrangement is located on the operator's cab and continuously scans a region located several meters ahead of the harvesting machine. The cross section of a windrow of crop material to be harvested by the pickup platform is evaluated on the basis of the profile of the windrow located in front of the harvesting machine. The edge of the windrow is identified on the basis of a sudden contour variation. The height of the windrow is determined on the basis of the measured distance values. Here the disadvantage is the fact that only the outer contours of the windrow are considered. A relatively dense windrow cannot be distinguished from a relatively sparse windrow with the same height.
U.S. Pat. No. 6,095,254 is directed to an agricultural machine with a boundary edge detection system. A laser sensor scans a region located ahead of the agricultural machine to detect and monitor the boundary edge. The boundary of the operation is recognized on the basis of the propagation time and the intensity or the phase shift of the reflected light. The arrangement described is not appropriate for the measurement of the amount of crop material to be harvested.
SUMMARY OF THE INVENTION
It is an object of the present invention to provide an improved system to measure the amount of crop material to be harvested prior to the crop material being taken up by the harvesting assembly of the harvesting machine.
The crop material to be harvested is exposed to electromagnetic radiation from a scanning device (particularly laser radiation). A receiver in the scanning device detects the electromagnetic radiation reflected by the crop material to resolve its location or its angle. In addition, the receiver measures the intensity of the reflected electromagnetic radiation. The receiver is in communication with a controller. The controller calculates the amount of crop material to be harvested based on the location and/or angle signal, and the intensity signal.
The receiver produces an at least one-dimensional signal resolved by location or angle. A two-dimensional signal taken by a camera is also conceivable. Here the transmitter and the receiver can be moved or pivoted in a manner known in itself together step-by-step or continuously over a measurement region, or only one of these. The controller has been provided with information as to which location or angle is to be associated with the signal received by the receiver. The use of a row of transmitters and/or receivers arranged alongside each other is also conceivable. There is also the possibility that a laser distance measurement sensor can be used in which the transmitter and/or the receiver is not rotated, but a mirror rotating continuously or step-by-step is used to scan the visible region. An angular region of up to 180° can be scanned. Such sensors are available from the Sick A. G., D-72796 Reute, under the designation LMS.
The invention proposes that the receiver detect the intensity or the amplitude of the reflected radiation that is a function of the number of plants per unit area and the dimensions of the plants. The measured intensity is considered in the determination of the amount of crop material to be harvested.
From the location and/or angle signals and the intensity signals the amount of crop material to be harvested can be calculated. The amount of crop material to be harvested can be defined as the volume of plants standing on a unit area. Thereby the amount can be measured in cubic meters of plant volume per square meter of the field, although other measurement units are also conceivable. It does not matter if the amount is calculated explicitly and transmitted in any particular form, used as an intermediate result in a further calculation or is incorporated in a calculation of the magnitude of an amount depending directly or indirectly on the amount. In this way with a known width of a harvesting assembly and a known forward velocity an expected crop throughput can be determined from the signals of the receiver.
Using this system an exact determination of the amount of crop material to be harvested can be calculated. Based on the known width of the harvesting assembly and the forward velocity of the harvesting machine the predicted crop load on the harvesting machine can be determined. This predicted crop load can be compared with an optimal crop load, and the forward speed of the machine adjusted accordingly to follow the optimal crop load. The predicted crop load measurement is performed at a distance ahead of the harvesting machine, so that in case of a variation in crop density the forward velocity can be adjusted in a timely manner. This increases the comfort of the operation and avoids critical situations in which the machine tends to jam. The conveying and separating processes in a harvesting machine can also be made to conform to the throughput amounts that can be expected in a timely manner, so that the resulting harvest is improved. Particular attention must be paid to the avoidance of jams that result from excessively high crop throughput.
As a rule the receiver is arranged to determine the distance to a point from the receiver and/or the transmitter to which the immediate output signal of the receiver is to conform. By scanning or sampling of a region located ahead of the harvesting machine a profile of the crop material to be harvested can be determined. In the controller, information can be generated about the width and/or the height of the stand of the plants that makes possible a precise determination of the amount.
The moisture of the plants can also be detected by a known moisture sensor, the output of which is communicated to the controller. The sensor can be arranged in the harvesting machine and detect the moisture of plants already harvested. The use of a sensor operating without contact, that operates, for example, with infra-red radiation, in order to detect the moisture of the plants before the harvesting process, is also conceivable. The moisture contains information about the density of the stand of the plants, that is, its mass per unit volume. On the basis of the measured values of the amount and the moisture, the mass density of the plants can be determined thereby (in units of plant mass per unit of area). If the width of the crop intake arrangement and the forward propulsion velocity are known, the mass throughput that is to be expected can be determined.
Dust in the air and on the plants are disturbance magnitudes whose effect can be largely eliminated by comparing the amount of crop material measured by the scanning device with crop throughput values calculated by sensors located on the harvesting machine. Therefore it is preferred that the controller be connected with an additional crop throughput sensor that measures the crop throughput in the harvesting machine. Crop throughput sensors have been proposed that measure the drive torque or the slip at the threshing cylinder or at the straw chopper. Position sensors on the feeder house, sheet metal baffle plates in the grain elevator, microwave sensors in the flow region of the crop, or sensors measuring the spacing between the pre-compression rolls may also be used to measure crop throughput.
The crop throughput values derived from the measurement values of the scanning device and the throughput values measured by the crop throughput sensor can be compared. In case of a deviation between the measured values for the crop throughput an error message can be transmitted that can instruct the operator to clean the transmitter and/or the receiver.
The crop that corresponds to the signal measured by the receiver interacts as a rule with the crop throughput sensor in the harvesting machine only after a time delay. It is appropriate therefore to consider the time delay between the two measurements in the controller.
It is also conceivable that the measurement value of the crop throughput sensor be used for calibrating the magnitude of the value calculated from the scanning device. Calibration is possible in which the mathematical connection is determined, for example, in the form of a correction table or curve between the magnitude determined from the measured values of the receiver and the measured value of the crop throughput sensor. Here the connection can be determined completely anew after a certain time interval so as to correspond to the immediate conditions (for example, optical qualities of the plants conditioned by weather conditions, time of day, moisture, type of plant, type of ground and ground condition, etc. as well as condition of the scanning device). In addition, with sufficient data, an expert system can be used to calibrate the scanning device. The controller can also be provided with information about the type of crop material to be harvested. The value of the amount generated from the signals of the scanning device is recalculated on the basis of a correction value determined by the data. In the measurement and/or the calibration according to the process described the height of cut of the cutting head can also be considered which can be measured by sensors on the cutting head itself or by the angle of the feeder house. The height of cut influences the amount of the straw taken up, but does not affect the amount of grain. If crop throughput sensors are used which measure only the grain throughput, this correction is worth considering.
As explained above, the controller is able to recognize boundaries of the crop material to be harvested. Accordingly it can be connected with a steering arrangement and guide a harvesting machine automatically along the edge of the crop material to be harvested.
Furthermore, the amount values provided by the controller can be used as input for the forward propulsion velocity of a harvesting machine. They can also be used to control the velocity of a crop conveying arrangement (for example, that of a feeder house) and parameters of crop processing arrangements (for example, the gap of a thresher cylinder and/or the rotational speed of the threshing cylinder). The amount values can also be referenced against their location in a field to generate a crop map.
The present invention can be used on agricultural combines or forage harvesters.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows a side view of a harvesting machine having the present invention.
FIG. 2 shows a block diagram of the present invention.
FIG. 3 shows a diagram that schematically reproduces the distances measured by a receiver.
FIG. 4 shows a diagram that schematically reproduces the intensities measured by a receiver.
FIG. 5 shows a flow chart on how the present invention operates.
DETAILED DESCRIPTION
A harvesting machine 10 shown in FIG. 1 is a combine that is supported on front driven and rear steerable wheels 12 and 14 respectively. The harvesting machine is provided with an operator's cab 16 from which it can be controlled by an operator. A grain tank 18 is located behind the operator's cab 16 . A discharge auger 20 is used to remove grain from the grain tank 18 and direct it to a receiving truck or grain cart. The grain tank 18 and operator's cab 16 are supported on a frame 22 formed by sidesheets. A harvesting assembly, not shown, directs harvested crop material to a feeder house 38 . The feeder house 38 is an upwardly inclined conveyor for directing the harvested crop material past stone trap 40 to the crop processing assemblies located between the sidesheets of the frame 22 . The harvested crop material from the feeder house 38 first encounters the threshing assembly formed by a transverse threshing cylinder 24 associated concave 26 and beater 28 . The threshing assembly threshes the harvested crop by separating the small crop components from the large crop components. The threshed crop mat is loosened by the separation assembly formed by straw walkers 30 . The straw walkers 30 expand the threshed crop material mat so that small components trapped in the mat can fall downwardly to the grain pan 32 . The grain pan 32 takes the small components from the threshing assembly and the separating assembly and direct these components to a cleaning assembly. The cleaning assembly comprises a cleaning shoe having sieves 34 over which the small components pass and a cleaning fan 36 that directs an air blast through the cleaning shoe. The light portions (chaff) of the small components is blown out the rear of the combine, whereas the heavier small components (clean grain) falls through the sieves 34 and is directed by augers and an elevator to the grain tank 18 .
Although the present invention is being illustrated on a conventional combine it may also be applied to rotary combines and other harvesting machines having different configurations.
The front of the operator's cab 16 is provided with a scanning laser device 42 that is in communication with a controller 44 . The controller 44 is also in communication with a crop throughput sensor 48 arranged in the feeder house 38 . The crop throughput sensor 48 measures the thickness harvested crop mat passing through the feeder house 38 . A velocity sensor 49 detects the conveying velocity of the feeder house 38 and is in communication with the controller 44 . A moisture sensor 50 is located downstream from the threshing cylinder 24 . The moisture sensor 50 is also in communication with the controller 44 and uses infra-red radiation to measure the moisture content of the threshed crop material. The controller 44 is also in communication with a drive 46 for rotating the threshing cylinder 24 and a variable speed transmission 64 for propelling the vehicle. For example the variable speed transmission could comprise a hydrostatic transmission, wherein a swash plate of a hydraulic pump that is connected with a hydraulic motor controls the forward propulsion velocity of the harvesting machine 10 .
As can be seen in FIG. 2, the scanning laser device 42 , the controller 44 , the drive 46 , the crop throughput sensor 48 , the velocity sensor 49 , the moisture sensor 50 and the variable speed transmission 64 are connected by a bus 52 . The bus 52 may be a CAN bus or an LBS bus.
The scanning laser device 42 includes a control arrangement 43 , that is connected with a transmitter 56 , a receiver 58 and a pivoting motor 54 . The transmitter 56 and the receiver 58 are mounted on a pivoting table 60 , that can be pivoted back and forth by the pivoting motor 54 about an axis 57 thereby scanning an arc located in front of the harvesting machine 10 . The electromagnetic (light) radiation radiated by the transmitter 56 may lie in the visible range or above or below the visible range. The transmitted electromagnetic radiation is directed to the ground several meters (for example, 10 meters) in front of the harvesting assembly in the direction of operation of the harvesting machine 10 . The receiver 58 detects the reflected radiation radiated by the transmitter 56 that is reflected from the ground, standing plants 62 or other objects. Since the radiation radiated from the transmitter 56 is amplitude modulated, the measurement of the propagation time can be used to detect the distance between the scanning laser device 42 and the point at which the radiation was reflected. The receiver 58 provides an output signal that contains information about the intensity (amplitude) of the reflected radiation in addition to the propagation time. The pivoting motor 54 is a stepper motor and pivots the pivoting table 60 continuously back and forth through an arc, for example, 30° degrees about the axis 57 . The control arrangement 43 is arranged for each pivot angle of the pivoting table 60 to detect the immediate angle, the distance from the point of reflection and the intensity of the radiation received by the receiver 58 . Following this the pivoting motor 54 is activated and the pivoting table 60 brought into another position. The control arrangement 43 has been provided with information about the immediate angle of the pivoting table 60 since it controls the pivoting motor 54 . A separate sensor would also be conceivable for the detection of the pivoting angle, in which case the stepper motor can be replaced by any desired motor. The pivoting table could be replaced with a rotating mirror.
FIGS. 3 and 4 reproduce examples of measurement values for the receiver 58 . At negative angles, that is, in the detection region located to the left of the direction of operation of the scanning laser device 42 , the measured distance “d” shown in FIG. 3 on the y axis is constant and relatively large and drops from an angle of approximately 0° (forward direction of operation at the longitudinal centerline of the harvesting machine) in one step to another constant but lower value. The measured intensity I shown in FIG. 4 on the y axis is constant at the negative angles and relatively low, increases with a step at approximately 0° and is also constant at angles above that, but at a higher level. The diagrams reproduced in FIGS. 3 and 4 correspond to a field on which plants stand only in the region above the angle of 0°,—that is, to the right of the longitudinal centerline of the harvesting machine 10 —since there the distance “d” to the scanning laser device 42 is smaller. In areas in which plants stand the reflectivity is higher than on the open ground, since the scanning laser device operates with infra-red radiation that is reflected to a greater degree by the plants 62 than by the ground. The edge of the stand of the crop is located at a pivot angle of 0°.
FIG. 5 shows a flow chart according to which the controller 44 operates. After the start in step 100 , in step 102 the control arrangement 43 is instructed to begin operation of the pivoting motor 54 so that the scanning laser device 42 scans a certain region of angles step by step ahead of the harvesting machine 10 . At that time the immediate pivoting angles, distance measurement values and intensity measurement values are stored in memory and transmitted to the controller 44 in step 104 .
In step 106 the amount of the plants 62 standing on the field is calculated on the basis of the measured values. Here the contour of the plants 62 is initially determined from the distance measurement values, that is, with consideration of the geometry of the entire measurement arrangement including its attachment to the harvesting machine 10 , the vertical cross section area (that is, the contour) of the standing front of the plants 62 is determined. This calculation can be performed as described in U.S. Pat. No. 6,095,254, which is incorporated herein by reference.
On the basis of the measured intensity a consideration of the density of the crop material follows in step 108 , that can be determined from the intensity measured in the crop material and the intensity upon clearing the ground (or the difference of the two intensities). The amount can then be determined from the width and the height or the cross sectional area and the density of the plants (by integration of the density over the area). The amount that is to be associated with a run through of the scanning laser device 42 over the range of angles is stored in memory in step 110 , where information about the point in time and/or the position, at which the measurement is taken is stored in memory along with the amount. The point in time can be determined with an appropriate clock, the position with a position determination system such as the appropriate GPS reference system.
In step 112 the throughput of the harvesting machine 10 is measured with the crop throughput sensor 48 and the velocity sensor 49 . The throughput is a function of the known width of the feeder house 38 , the pressures of the mass of the crop measured in the crop throughput sensor 48 and the conveying velocity of the feeder house 38 , that is measured with the velocity sensor 49 . The throughput (volume per unit of time) is determined from the measured values of the aforementioned sensors.
In step 114 the throughput determined in step 112 in the harvesting machine is compared with a theoretical throughput. The theoretical throughput is calculated on the basis of the amount that was stored in step 110 and the forward velocity of the harvesting machine 10 , there the values stored in memory are used, that correspond to the point in time or the position at which the plants 62 stand whose throughput was measured in step 112 in the harvesting machine 10 . In case the comparison in step 114 does not result in an agreement between the two values (or at least approximate agreement), step 116 follows, in which an error message is transmitted. On the basis of the error message the operator can recognize that a verification of the scanning laser device 42 is required. Then a manual repositioning of the forward propulsion velocity and the remaining parameters is also useful which can otherwise be adjusted automatically.
If the values agree, step 118 follows, in which the controller 44 adjusts the forward propulsion velocity of the harvesting machine 10 by means of the variable speed transmission 64 to a value that corresponds to an optimum loading of the harvesting machine 10 on the basis of the amount values stored in memory in step 110 . Here the time interval is considered until the harvesting machine 10 reaches the location at which the plants 62 stand that correspond to the measured amount value. In addition the rotational speed of the threshing cylinder is adjusted through the controller by means of the drive 46 to correspond to a value measured in step 110 and the moisture measured by the moisture sensor 50 .
Step 118 is again followed by step 102 . In this way a series of measured values of the amount is continuously generated that are used with consideration of the forward velocity of the harvesting machine with the appropriate time delay for the control of the forward velocity control.
Having described the preferred embodiment, it will become apparent that various modifications can be made without departing from the scope of the invention as defined in the accompanying claims. | A system for measuring the amount of crop material located on a field to be harvested uses a scanning laser device. The scanning laser device has a transmitter for emitting electromagnetic radiation, a receiver for receiving reflected radiation from the crop material and providing resolution in terms of location and/or angle from which the reflected radiation was received. The receiver also generates an intensity signal indicating the intensity of the reflected electromagnetic radiation. A controller is in communication with the scanning laser device and determines the amount of the crop material located on the field on the basis of the crop material location signals and the intensity signals received from the receiver. | 0 |
LIST OF PRIOR ART (37 CFR 1.56(a))
The following references are cited to show the state of the art:
Japanese Patent Kokoku (Post-Exam. Publn.) No. 20,954/75
Japanese Patent Kokoku (Post-Exam. Publn.) No. 20,955/75
Japanese Patent Kokai (Laid-Open) No. 133,239/74
Japanese Patent Kokai (Laid-Open) No. 105,942/76
Japanese Patent Kokai (Laid-Open) No. 109,239/76
BACKGROUND OF THE INVENTION
The present invention relates to anti-crevice corrosion sealants for metals which can restrain crevice corrosion occurring at fine crevices formed between the elements of metal machinery and tools or on the jointed interior surface of the elements.
It is known that corrosion, referred to as "crevice corrosion" in the art occurs at fine crevices between the elements of metal machinery and tools, for example, the joined interior surfaces of flanges or the crevice between the screw surface of a bolt and a tapped hole when said metal machinery and tools are used in water or sea water (hereinafter referred to simply as "sea water, etc."). This phenomenon appears particularly remarkably in sea water rather than in fresh water and in the case of stainless steel or aluminum which are easy to be brought to a passive state.
It is considered that one reason for the crevice corrosion is an oxygen concentration cell action due to a difference between the oxygen concentration in the liquid present in crevices and the oxygen concentration at parts remote from crevices. Further, a reduction of the pH of the liquid in crevices due to the dissolution of the metal surface is considered to be another reason therefor.
As a process for restraining crevice corrosion, there have heretofore been known a process which comprises coating a paint onto the head of a bolt after bolting and a process which comprises covering the head of a bolt with a lining material. According to the process which comprises coating a paint, however, it is inevitable that the liquid penetrates into the crevices after use for a long period of time. Such is also the case with the process which comprises covering with a lining material. In both of the processes, crevice corrosion occurs. Further, there are a process which comprises adding a cation exchange substance into crevices to remove chloride ion and restrain crevice corrosion, a process which comprises applying a sheet impregnated with an alkali such as sodium silicate to crevices and prevent the acidification of the liquid in the crevice, and a process which comprises adding an inhibitor of chromate and bichromate series, nitrate series or primary, secondary and tertiary phosphates series to crevices. However, all the processes can not obtain a satisfactory anticorrosion effect.
Therefore, an object of the present invention is to obviate the above-mentioned defects of prior art anti-crevice corrosion sealants (hereinafter referred to simply as "sealants") for metals.
Another object of the invention is to provide a sealant for metals which can restrain the occurrence of crevice corrosion by filling it into crevices.
The other objects and advantages of the present invention will be apparent from the following description.
BRIEF DESCRIPTION OF THE INVENTION
According to the present invention, there is provided a sealant for metals comprising a mixture of zinc powder and dicyclohexylammonium nitrite powder, a vinyl silane coupling agent and film-forming polystyrene dissolved in a solvent. Crevice corrosion can be restrained effectively by filling the sealant into fine crevices between a bolt and a tapped hole or onto the interior jointed surface of the elements of stainless steel machinery and tools.
BRIEF DESCRIPTION OF THE DRAWING
The accompanying drawing shows a corrosion tester for measuring the effect of the sealant for metals according to the present invention.
DETAILED DESCRIPTION OF THE INVENTION
The sealant for metals according to the present invention comprises a material obtained by adding zinc powder and dicyclohexylammonium nitrite powder to a vinyl silane coupling agent, film-forming polystyrene dissolved in a solvent and optionally a phthalic acid ester.
More specifically, the sealant for metals according to the present invention comprises 4 to 15 parts by weight of a mixture consisting of 5 to 30% by weight of a material obtained by adding 4 to 15 parts by weight of a mixture consisting of 99 to 80% by weight of zinc powder (particle size 0.001 to 0.1 mm) and 1 to 20% by weight of dicyclohexylammonium nitrite powder (particle size 0.001 to 0.1 mm) to 1 part by weight of a vinyl silane coupling agent and 95 to 70% by weight of a solution obtained by adding 5 to 40% by weight of polystyrene to 95 to 60% by weight of a solvent of ethyl acetate series.
In order to impart plasticity to the sealant, the sealant may comprise 5 to 30% by weight of said material and 95 to 70% by weight of a solution obtained by adding 5 to 40% by weight of a mixture consisting of film-forming polystyrene and a small amount (1 to 10% by weight) of a phthalic acid ester to 95 to 60% by weight of a solvent of ethyl acetate series.
It is preferable that the particle size of zinc powder is 0.001 to 0.1 mm. The particle size of less than 0.001 mm is uneconomical in that the cost of pulverization is increased. At a particle size of more than 0.1 mm, dispersion becomes uneven and adhesiveness of the sealant to the metal surface becomes poor, resulting in the reduction of anticorrosion effect.
As for the amount of dicyclohexylammonium nitrite powder added to zinc powder, the amount of less than 1% by weight can not give satisfactory anticorrosion effect. Also, if the amount is more than 20% by weight, dispersion becomes uneven and sealing property is deteriorated on the exhaustion of dicyclohexylammonium nitrite.
As for the amount of a mixture of zinc powder and dicyclohexylammonium nitrite powder added to a vinyl silane coupling agent, when the amount is less than 4 times the weight of the vinyl silane coupling agent, satisfactory anticorrosion effect can not be obtained. Also, when the amount is more than 5 times the weight of the vinyl silane coupling agent, viscosity is lost and adhesiveness is reduced.
As the vinyl silane coupling agent, there may be used, for example, vinyltrichlorosilane, vinyltriethoxysilane, vinyltricellosolve ester silane, vinyltrimethoxysilane, vinyltris(2-methoxyethoxy) silane, etc. which are all commercially available.
Also, as the phthalic acid ester, there may be used any phthalic acid ester which is generally used as a plasticizer, for example, dibutyl phthalate, di-2-ethylhexyl phthalate, di-n-octyl phthalate, diisooctyl phthalate, dilauryl phthalate, butyloctyl phthalate, butyldecyl phthalate, butylauryl phthalate, butylphthalyl butylglycollate, etc.
As for the amount of a mixture of zinc powder, dicyclohexylammonium nitrite powder and a vinyl silane coupling agent added to a polystyrene solution, sealing property is poor when the amount is less than 5% by weight. Also, when the amount is more than 30% by weight, satisfactory anti-corrosion effect can not be obtained.
In the prevention of crevice corrosion of metals, the above-mentioned compositions act effectively. As for said oxygen concentration cell action, dicyclohexylammonium nitrite acts effectively. Specifically, the cyclohexyl nucleus-containing nitrite group of dicyclohexylammonium nitrite is vaporized in a molecular state in crevices and adsorbed onto the metal surface. Thus, a passive film is formed on the metal surface. Thereby, even if sea water, etc. penetrate crevices, oxygen consumption in the crevices is suppressed and a difference in oxygen concentration does not occur. Therefore, the occurrence of crevice corrosion can be restrained by said oxygen concentration cell action.
Also, when machinery and tools are used in sea water, etc. for a long period of time, the sealing property of the corrosion inhibitor is deteriorated, and sea water, etc. penetrate into crevices, zinc acts effectively. It is well known that zinc shows in sea water, etc. a less noble potential than iron, stainless steel and aluminum. Therefore, zinc present on the metal surface is dissolved in preference to said metals, and the dissolution of the metal surface is suppressed. Further, the dissolved zinc combines with the hydroxyl ion (OH - ) of sea water, etc. in the crevices to form amorphous zinc hydroxide Zn(OH) 2 . Since the pH in the crevices is maintained at 10-11 by the zinc hydroxide, the oxide film of the metal surface is stably protected.
Also, since the zinc hydroxide is surrounded by polystyrene film, the zinc hydroxide is difficult to be eluted and remains in the crevices. Thus, the anti-corrosion effect can be retained for a long period of time. Other advantageous properties of this invention result from the fact that metallic zinc particles are encapsulated by thin polystyrene films, but after the solvent for polystyrene polymer dries, many micro-cracks occur at the surface of polystyrene encapsulation, thus bringing metallic zinc particles into contact with the crevice metal surface.
Furthermore, the liquid penetrates to the encapsulated zinc through the micro-cracks and reacts with the metallic zinc to form amorphous zinc hydroxide which is effective to prevent crevice corrosion. The thin polystyrene shell prevents the zinc hydroxide from diffusing out of the crevice and the thus remaining zinc hydroxide can prevent crevice corrosion for a long period of time.
The following example illustrates the present invention.
EXAMPLE
Test pieces 1 and 2 of stainless steel (chemical composition of which is shown in Table 1) as shown in the accompanying drawing are prepared. These test pieces 1 and 2 are assembled by filling the following sealants-1 to -3 into the fine crevice formed by the test pieces 1 and 2.
Sealant-1 (Referential Example)
(a) Preparation of a mixed powder--90% by weight of zinc dust (particle size 0.005-0.05 mm) is mixed with 10% by weight of dicyclohexylammonium nitrite powder (particle size 0.001 to 0.1 mm).
(b) 1 Part by weight of vinyl silane coupling agent is added to 3.5 parts by weight of the mixed powder obtained in (a).
(c) 20% by weight of the material obtained in (b) above is mixed with 80% by weight of a polystyrene solution obtained by mixing 70% by weight of ethyl acetate with 30% by weight of polystyrene.
Sealant-2
4 Parts by weight of the mixed powder obtained in the same manner as in said Sealant-1 is mixed with 1% by weight of vinyl silane coupling agent. A sealant is prepared by the use of the material thus obtained in the same manner as in (c) above.
Sealant- 3
15 Parts by weight of the mixed powder obtained in the same manner as in said Sealant-1 is mixed with 1 part by weight of vinyl silane coupling agent. A sealant is prepared by the use of the material thus obtained in the same manner as in (c) above.
The test pieces 1 and 2, assembled as described above, are dipped in a 3% aqueous sodium chloride solution at 25° C. for 720, 1440 and 4320 hours, respectively. The test pieces 1 and 2 are then removed from the solution and the test piece 1 is drawn out to observe the occurrence of corrosion in crevice. Further, the penetration of the solution into a reservoir 3, sealing property and the pH of the solution in the reservoir are measured. The results obtained are shown in Table 2. Also, for comparison, the results of a prior art sealing material closest to the sealants of the present invention are shown in the table. It is found from the table that the sealants of the present invention are more effective than the prior art sealing material.
Table 1______________________________________Chemical composition oftest pieces (%)C Si Mn P S Cr Ni______________________________________0.07 0.90 1.25 0.010 0.009 19.30 9.62______________________________________
Table 2______________________________________Dip test resultsSealing Measurement Time (hours)materials item 720 1440 4320______________________________________Prior art pH 8-9 8-9 6-7sealing Penetration No No Yes*materialSealant-1 pH 9-10 9-10 8-9 Penetration No Yes *Sealant-2 pH 10-11 10-11 10-11 Penetration No No NoSealant-3 pH 10-11 10-11 10-11 Penetration No No No______________________________________ Note: 1. *Crevice corrosion was observed. 2. pH values represent minimum value and maximum value. | Anti-crevice corrosion sealants for metals obtained by adding a mixture of zinc powder and dicyclohexylammonium nitrite powder bound by a vinyl silane coupling agent to a film-forming polystyrene dissolved in a solvent can restrain crevice corrosion occurring at crevices or jointed interior surfaces by filling the sealants into a fine crevice formed between the elements of metal machinery and tools or onto the jointed interior surface of the elements. | 2 |
SUMMARY OF THE INVENTION
This invention relates to novel compounds of structural formula I which are angiotensin II (AII) agonists that bind to the AT 1 and AT 2 receptor sites and produce a pharmacologic response. In general, these compounds will be useful in the treatment of any condition in which endogenous production of AII is deficient or the increased effects of AII are considered desirable, although not limited to such conditions.
It also relates to processes for preparing the novel compounds of the invention, their pharmaceutical formulations, and their use as a method of treatment of hypotension and secondary hypoaldosteronism.
BACKGROUND OF THE INVENTION
Renin-angiotensin system (RAS) plays a central role in the regulation of normal blood pressure as well as volume and elecrolyte homeostasis. Angiotensin II (AII), an octapeptide hormone is produced mainly in the blood during the cleavage of angiotensin I by angiotensin converting enzyme (ACE) localized on the endothelium of blood vessels of lung, kidney, and many other organs, and is the end product of the RAS. AII is a powerful arterial vasoconstrictor that exerts its action by interacting with specific receptors present on cell membranes. One of the possible modes of controlling the RAS is angiotensin II receptor antagonism. Several peptide analogs of AII are known to inhibit the effect of this hormone by competitively blocking the receptors, but their experimental and clinical applications have been limited by the partial agonist activity and lack of oral absorption [M. Antonaccio. Clin,. Exp. Hypertens. A4, 27-46 (1982); D. H. P. Streeten and G. H. Anderson, Jr. Handbook of Hypertension, Clinical Pharmacology of Antihypertensive Drugs, ed. A. E. Doyle, Vol. 5, pp. 246-271, Elsevier Science Publisher, Amsterdam, The Netherlands, 1984].
Recently, several non-peptide compounds have been described as AII antagonists. Illustrative of such compounds are those disclosed in U.S. Pat. Nos. 4,207,324; 4,340,598; 4,576,958; 4,582,847; and 4,880,804; in European Patent Applications 028,834; 245,637; 253,310; and 291,969; and in articles by A. T. Chiu, et al. [Eur. J. Pharm. Exp. Therap, 157, 13-21 (1988)]and by P. C. Wong, et al. [J. Pharm, Exp. Therap, 247, 1-7(1988)]. All of the U.S. Patents, European Patent Applications 028,834 and 253,310 and the two articles disclose substituted imidazole compounds which are generally bonded through a lower alkyl bridge to a substituted phenyl. European Patent Application 245,637 discloses derivatives of 4,5,6,7-tetrahydro-2H-imidazo[4,5-c]-pyridine-6-carboxylic acid and analogs thereof as antihypertensive agents.
The pharmocological effects of angiotensin II agonism are generally described in Goodman and Gilman's, "The Pharmological Basis of Therapeutics"(8th ed, 1990). Of particular note are sections VI, Drugs Affecting Renal Function and Electrolyte Metabolism and sections VII, Cardiovascular Drugs.
Imidazo[4,5-b]pyridines beating a thiophene ring are disclosed in U.S. Pat. No. 5,177,074, issued on Jan. 5, 1993 as novel angiotensin II antagonists. The instant application discloses a select group of compounds which are angiotensin II agonists useful in the treatment of hypotension.
DETAILED DESCRIPTION OF THE INVENTION
This invention relates to angiotensin II agonists of structural formula I shown below and which are useful in the treatment of hypotension: ##STR2## or a pharmaceutically acceptable salt thereof, wherein: R 1 is: n-butyl or isobutyl; and
R 2 is: O-n-butyl or CH 2 -O-n-butyl. ##STR3##
The synthetic routes used to prepare the angiotensin II agonists of structural formula I are illustrated in schemes I and II. The dianion of sulfonamide 1 generated with two equivalents of a strong base, such as n-BuLi, is quenched with an appropriate alkyl halide to afford the 5-substituted thiophene, 2. The dianion of 2, generated with two equivalents of a strong base, was quenched with triisopropyl borate to afford, after acid work up, boronic acid derivative 3. Palladium catalyzed coupling of 3 with 4-halo-benzyl imidazopyridine derivative 4 provides the coupled product 5. Deprotection of the sulfonamide with TFA affords 6. Coupling of 6 with a chloroformate in pyridine or an activated acid, prepared with CDI, affords the completed agonists, 7. Alternatively, illustrated in scheme II, the boronic acid derivative 3 can be coupled with 4-bromobenzyl alcohol to provide biaryl 9, after conversion of the alcohol to the bromide with PBr 3 . Coupling of the benzylbromide with the sodium salt of the imidazopyridine provides 5, which is then further elaborated as described in scheme I.
It will be appreciated by those skilled in the art that functional group transformations can be conducted on aryl and heterocyclic rings to afford desired analogs. For example, esters may be converted to amides by heating them with amines and an amide nitrogen if present in the heterocycle may be alkylated using bases such as sodium hydride in DMF with the appropriate alkyl halide. Functional group protection throughout these syntheses will be chosen to be compatible with subsequent reaction conditions. Ultimately such protecting groups will be removed to generate the desired optimally active compounds of Formula I.
The compounds of this invention form salts with various inorganic and organic acids and bases which are also within the scope of the invention. Such salts include ammonium salts, alkali metal salts like sodium and potassium salts, alkaline earth metal salts like the calcium and magnesium salts, salts with organic bases; e.g., dicyclohexylamine salts, N-methyl-D-glucamine, salts with amino acids like arginine, lysine, and the like. Also, salts with organic and inorganic acids may be prepared; e.g., HCl, HBr, H 2 SO 4 , H 3 PO 4 , methanesulfonic, toluenesulfonic, maleic, furnaric, camphorsulfonic. The non-toxic, physiologically, acceptable salts are preferred, although other salts are also useful; e.g., in isolating or purifying the product.
The salts can be formed by conventional means such as by reacting the free acid or free base forms of the product with one or more equivalents of the appropriate base or acid in a solvent or medium in which the salt is insoluble, or in a solvent such as water which is then removed in vacuo or by freeze-drying or by exchanging the cations of an existing salt for another cation on a suitable ion exchange resin.
Angiotensin II (AII) is a powerful arterial vasoconstrictor, and it exerts its action by interacting with specific receptors present on cell membranes. The compounds described in the present invention act as agonists of AII at the receptors. In order to identify binding activity and determine their affinity in vitro, the following ligand-receptor binding assays were used along with binding assays reported in the literature (R. S. Chang et al, Biochem. Biophys. Res, Commun. 1990, 171, 813.)
Receptor binding assay using rabbit aorta membrane preparation
Three frozen rabbit aorta (obtained from Pel-Freeze Biologicals) were suspended in 5 mM Tris-0.25M Sucrose, pH 7.4 buffer (50 ml) homogenized, and then centrifuged. The mixture was filtered through a cheesecloth and the supernatant was centrifuged for 30 minutes at 20,000 rpm at 4° C. The pellet thus obtained was resuspended in 30 ml of 50 mM Tris-5 mM MgCl 2 buffer containing 0.2% Bovine Serum Albumin and 0.2 mg/ml Bacitration and the suspension was used for 100 assay tubes. Samples tested for screening were done in duplicate. To the membrane preparation (0.25 ml) there was added 125 I-Sar 1 Ile 8 -angiotensin II [obtained from New England Nuclear] (10 ul; 20,000 cpm) with or without the test sample and the mixture was incubated at 37° C. for 90 minutes. The mixture was then diluted with ice-cold 50 mM Tris-0.9% NaCl, pH 7.4 (4 ml) and filtered through a glass fiber filter (GF/B Whatman 2.4" diameter). The filter was soaked in scintillation cocktail (10 ml) and counted for radioactivity using Packard 2660 Tricarb liquid scintillation counter. The inhibitory concentration (IC 50 ) of potential AII antagonist which gives 50% displacement of the total specifically bound 125 I-Sar 1 Ile 8 -angiotensin II was presented as a measure of the potency of such compounds as AII antagonists.
Receptor assay using Bovine adrenal cortex preparation
Bovine adrenal cortex was selected as the source of AII receptor. Weighed tissue (0.1 g is needed for 100 assay tubes) was suspended in Tris.HCl (50 mM), pH 7.7 buffer and homogenized. The homogenate was centrifuged at 20,000 rpm for 15 minutes. Supernatant was discarded and pellets resuspended in buffer [Na 2 HPO 4 (10 mM)-NaCl (120 mM)-disodium EDTA (5 mM) containing phenylmethane sulfonyl fluoride (PMSF) (0.1 mM)]. (For screening of compounds, generally duplicates of robes are used). To the membrane preparation (0.5 ml) there was added 3H-angiotensin II (50 mM) (10 ul) with or without the test sample and the mixture was incubated at 37° C. for 1 hour. The mixture was then diluted with Tris buffer (4 ml) and filtered through a glass fiber filter (GF/B Whatman 2.4" diameter). The filter was soaked in scintillation cocktail (10 ml) and counted for radioactivity using Packard 21560 Tricarb liquid scintillation counter. The inhibitory concentration (IC 50 ) of potential AII antagonist which gives 50% displacement of the total specifically bound 3 H-angiotensin II was presented as a measure of the potency of such compounds as AII antagonists.
Using the methodology described above, representative compounds of this invention were evaluated and were found to exhibit an activity of at least IC 50 <50 μM, thereby demonstrating and confirming the binding of the compounds of the invention to the AII receptors.
The hypertensive effects of the compounds described in the present invention may be evaluated using the methodologies described below:
I: Male Sprague-Dawley rats (200-400 grams body weight) were anesthetized with a short-acting barbiturate (50 mg/kg i.p. methohexital) and instrumented with two chronic vascular catheters the afternoon before the experiment. A catheter in the femoral vein was used for intravenous administration of test compound and test challenges with pressor agents (AII or methoxamine). Rats were permitted to recover overnight from anesthesia and allowed free acces to water. Food was withheld if test compound was administered orally.
Following calibration of pressure transducers and appropriate equilibration, rats were challenged with bolus doses of AII (0.1 μg/kg) and methoxamine (50 μg/kg) to insure patency of catheters and responsiveness of preparation. Rats were then dosed orally or intravenously with the test compound. Blood pressure was continuously monitored throughout the study. Percent inhibition of the pressor responses to AII challenges during the subsequent 6 hours and at 24 hours was used as a measure of AII inhibition. If the test compound increased blood pressure it was considered to be a potential AII agonist and exogenous AII challenges were not administered.
II: Male Charles River Sprague-Dawley rats (300-375 gm) were anesthetized with methohexital (Brevital; 50 mg/kg i.p.) and the trachea was cannulated with PE 205 tubing. A stainless steel pithing rod (1.5 mm thick, 150 mm long) was inserted into the orbit of the right eye and down the spinal column. The rats were immediately placed on a Harvard Rodent Ventilator (rate--60 strokes per minute, volumn--1.1 cc per 100 grams body weight). The fight carotid artery was ligated, both left and right vagal nerves were cut, and the left carotid artery was cannulated with PE 50 robing for drag administration, and body temperature was maintained at 37° C. by a thermostatically controlled heating pad which received input from a rectal temperature probe. Atropine (1 mg/kg i.v.) was then administered, and 15 minutes later propranolol (1 mg/kg i.v.). Thirty minutes later agonists of formula I were administered intravenously. Blood pressure was then monitored for the duration of the experimental period approximately six hours.
The compounds of the invention are useful in treating hypotension. These compounds may also be expected to be useful in the treatment of hypoaldosteronism, pulmonary hypotension, renal failure, shock, deficiency of antidiuretic hormone, as well as in other conditions in which the maintenance of blood pressure and blood volume would be considered advantageous see Goodman and Gilman: The Pharmacological Basis of Therapeutics (sixth edition). Additionally, the compounds of this invention may be useful for enhancing memory and cognition and also for inotropic support of the heart. The application of the compounds of this invention for these and similar disorders will be apparent to those skilled in the art.
In the management of hypotension and the clinical conditions noted above, the compounds of this invention may be utilized in compositions such as tablets, capsules or elixirs for oral administration, suppositories for rectal administration, sterile solutions or suspensions for parenteral or intramuscular administration, and the like. The compounds of this invention can be administered to patients (animals and human) in need of such treatment in dosages that will provide optimal pharmaceutical efficacy. Although the dose will vary from patient to patient depending upon the nature and severity of disease, the patient's weight, special diets then being followed by a patient, concurrent medication, and other factors which those skilled in the art will recognize, the dosage range will generally be about 1 to 1000 mg. per patient per day which can be administered in single or multiple doses. Preferably, the dosage range will be about 2.5 to 250 mg. per patient per day; more preferably about 5 to 150 mg. per patient per day.
Typically, the individual daily dosages for these combinations can range from about one-fifth of the minimally recommended clinical dosages to the maximum recommended levels for the entities when they are given singly.
About 1 to 100 mg. of compound or mixture of compounds of Formula I or a physiologically acceptable salt is compounded with a physiologically acceptable vehicle, carrier, excipient, binder, preservative, stabilizer, flavor, etc., in a unit dosage form as called for by accepted pharmaceutical practice. The amount of active substance in these compositions or preparations is such that a suitable dosage in the range indicated is obtained.
Illustrative of the adjuvants which can be incorporated in tablets, capsules and the like are the following: a binder such as gum tragacanth, acacia, corn starch or gelatin; an excipient such as microcrystalline cellulose; a disintegrating agent such as corn starch, pregelatinized starch, alginic acid and the like; a lubricant such as magnesium stearate; a sweetening agent such as sucrose, lactose or saccharin; a flavoring agent such as peppermint, oil of wintergreen or cherry. When the unit dosage unitform is a capsule, it may contain, in addition to materials of the above type, a liquid carrier such as fatty oil. Various other materials may be present as coatings or to otherwise modify the physical form of the dosage unit. For instance, tablets may be coated With shellac, sugar or both. A syrup or elixir may contain the active compound, sucrose as a sweetening agent, methyl and propyl parabens as preservatives, a dye and a flavoring such as cherry or orange flavor.
Sterile compositions for injection can be formulated according to conventional pharmaceutical practice by dissolving or suspending the active substance in a vehicle such as water for injection, a naturally occurring vegetable oil like sesame oil, coconut oil, peanut oil, cottonseed oil, etc., or a synthetic fatty vehicle like ethyl oleate or the like. Buffers, preservatives, antioxidants and the like can be incorporated as required.
The following examples further illustrate the preparation of the compounds of Formula I and their incorporation into pharmaceutical compositions and, as such, are not to be considered or construed as limiting the invention recited in the appended claims.
EXAMPLE 1
5-butyl-2-(N-t-butylaminosulfonyl)thiophene
To a solution of 2-(N-t-butylaminosulfonyl)thiophene (2.01 g, 9.18 mmol) in anhydrous THF (17 mL) cooled to -78° C. under N 2 was added 2.5 M n-BuLi (10 mL, 2.7 equiv). After stirring at -78° C. for 30 min the bath temperature was raised to -40° C. and the mixture was stirred for an additional 2 hrs. To this mixure was added n-butyliodide (2.0 mL, 2 equiv) and the reaction was allowed to warm to room temperature. After stirring overnight the darkened reaction mixture was quenched with NH 4 Cl soln and extracted with EtOAc. The organic was washed with brine and dried over anhydrous MgSO 4 and concentrated in vacuo. The titled compound was purified by flash chromatography eluting with hex/EtOAc (15:1 to 7:1). Rf=0.32 (6:1 Hex/EtOAc).
EXAMPLE 2
5-isobutyl-2-(N-t -butylaminosulfonyl)thiophene
The titled compound was prepared using the procedure described for the synthesis of 5-butyl-2-(N-t-butylaminosulfonyl)-thiophene by substituting isobutyliodide for butyliodide. Rf=0.37 (6:1 Hex/EtOAc).
1 H NMR (400 MHz, CDCl 3 ) δ0.92 (d, 6H), 1.26 (s, 9H), 1.86 (m, 1H), 2.66 (d, 2H), 4.58 (s, 1H), 6.65 (d, 1H), 7.40 (d, 1H).
EXAMPLE 3
5,7-dimethyl-2-ethyl-3-[[4-[2-[(butyloxycarbonyl)aminosulfonyl]-5-isobutyl-3-thienyl]phenyl]methyl]imidazo[4,5- b]pyridine
Step A; Preparation of 5-isobutyl-2-(N-t-butylaminosulfonyl)-thiophene-3-boric acid
To a solution of 5-isobutyl-2-(t-butylsulfonamido)thiophene (1.6 g, 5.82 mmol) in anhydrous THF cooled to -78° C. under N 2 was added 2.5M n-BuLi (5.8 mL, 2.5 equiv). The reaction was allowed to warm to -20° C. over a 4 h period. The reaction mixture was stirred for an additional hr at -20° C. To this mixture was added triisopropylborate (2.0 mL, 1.5 equiv). The mixture was warmed to room temperature and stirred overnight. The next day the reaction was quenched with 2N HCl (3 mL) and stirred until the gelatinous solid had dissolved. The mixture was extracted with EtOAc and washed with brine and dried over MgSO 4 . The organic was concentrated in vacuo to afford the titled product Rf=0.40 (1:1 EtOAc/hex).
Step B: Preparation of 5,7-dimethyl-2-ethyl-3-[[4-[2-(N-t-butylaminosulfonyl)-5-iso-butyl-3-thienyl]phenyl]methyl]-imidazo[4,5-b ]pyridine
To a solution of 5,7-dimethyl-2-ethyl-3-[[4-iodophenyl]-methyl]imidazopyridine (948 mg, 2.42 mmol) and the product of step A (1.15 g, 3.61. mmol) in toluene (32 mL) was added 1.25N NaOH (7.5 mL), EtOH (8 mL) and Pd(PPh 3 ) 4 (156 mg, 3 mol %). The reaction mixture was stirred at reflux under N 2 for 2 h. After cooling to room temperature the reaction was extracted with EtOAc and washed with 1N NaOH and brine. The organic was dried over anhydrous MgSO 4 and concentrated in vacuo. The titled compound was purified by flash chromatography eluting with 1.5:1 hex/EtOAc.
1 H NMR (200 MHz, CD 3 OD) ε0.94 (s, 9H), 0.96 (d, 6H), 1.29 (t, 3H), 1.89 (m, 1H), 2.57 (s, 3H), 2.60 (s, 3H), 2.70 (d, 2H), 2.86 (q, 2H), 5.58 (s, 2H), 6.82 (s, 1H), 7.01 (s, 1H), 7.19 (d, 2H), 7.55 (d, 2H).
Step C: Preparation of 5,7-dimethyl-2-ethyl-3-[[4-[2-(aminosulfonyl)-5-isobutyl-3-thienyl]phenyl]methyl]imidazo[4,5b]pyridine
To a mixture of the product of step B (872 mg, 1.62 mmol) and anisole (2 drops) was added TFA (5 mL). After standing at room temperature overnight the reaction was concentrated in vacuo. The residue was dissolved in EtOAc and washed with 2 N Na 2 CO 3 soln, and brine. The organic was dried over anhydrous MgSO 4 and concentrated in vacuo to provide the titled compound, Rf=0.35 (2:1 EtOAc/Hex).
Step D: Preparation of 5,7-dimethyl-2-ethyl-3-[[4-[2-[(butyloxycarbonyl)aminosulfonyl]-5-isobutyl-3-thienyl]phenyl]-methyl]imidazo[4,5-b]pyridine
To a solution of the product of step 3 (404 mg, 0.84 mmol) in anhydrous pyridine (3 mL) cooled to 0° C. was added 4-pyrrolidinopyridine (124 mg) and butylchloroformate (1.15 mL, 10 equiv). The next day the reaction was quenched with MeOH and concentrated in vacuo. The residue was dissolved in EtOAc and washed with 10% citric acid, H 2 O and brine. The organic was dried over anhydrous MgSO 4 and concentrated in vacuo. The titled compound, Rf=0.56 (40:10:1 CHCl 3 /MeOH/NH 4 OH), was purified by flash chromatography eluting with 80:10:1 (CHCl 3 /MeOH/NH 4 OH).
1 H NMR (400 MHz, CD 3 OD)ε0.83 (t, 3H), 0.97 (d, 6H), 1.21 (m, 2H), 1.30 (t, 3H), 1.42 (m, 2H), 1.93 (m, 1H), 2.58 (s, 3H), 2.61 (s, 3H), 2.71 (d, 2H), 2.89 (q, 2H), 3.93 (t, 2H), 5.59 (s, 2H), 6.84 (s, 1H), 7.03 (s, 1H), 7.17 (d, 2H), 7.46 (d, 2H).
EXAMPLE 4
5,7-dimethyl-2-ethyl-3-[[4-[2-[(butyloxymethylcarbonyl)aminosulfonyl]-5-isobutyl-3-thienyl]phenyl]methyl]imidazo[4,5-b]pyridine
To a solution of butoxyacetic acid (0.028 mL, 0.218 mmol) in dry THF (1 mL) was added CDI (35 mg, 0.22 mmol). After stirring. at 50° C. for 2.5 h, a solution of the product of Example 3, step C (35 mg. 0.073 mmol) and DBU (0.033 ml, 0.218 mmol) in THF (1 mL) was added. The reaction mixture was stirred at 50° C. overnight. The next day the reaction was quenched MeOH and the solvent was removed in vacuo. The residue was dissolved in EtOAc and washed with 10% citric acid solution, H 2 O and brine. The organic was dried over anhydrous MgSO 4 and concentrated in vacuo. The titled compound, Rf=0.58 (40:10:1 CHCl 3 /MeOH/NH 4 OH), was purified by flash chromatography eluting with 80:10:1 (CHCl 3 /MeOH/NH 4 OH).
1 H NMR (400 MHz, CD 3 OD) ε0.84 (t, 3H), 0.97 (d, 6H), 1.22 (m, 2H), 1.32 (t, 3H), 1.41 (m, 2H), 1.91 (m, 1H), 2.58 (s, 3H), 2.61 (s, 3H), 2.71 (d, 2H), 2.90. (q, 2H), 3.21 (t, 2H), 3.53 (s, 2H), 5.60 (s, 2H), 6.82 (s, 1H), 7.02 (s, 1H), 7.18 (d, 2H), 7.49 (d, 2H).
EXAMPLE 5
5,7-dimethyl-2-ethyl-3-[[4-[2-[(butyloxycarbonyl)aminosulfonyl]-5-butyl-3-thienyl]phenyl]methyl]imidazo[4.5-b]pyridine
Step A: Preparation of 5-butyl-2-(N-t-butylaminosulfonyl)-thiophene-3-boric acid
To a solution of the product of Example 1 (1.52 g, 5.53 mmol) in anhydrous THF (12 mL) cooled to -78° C. under N 2 was added 2.5M n-BuLi (5.53 mL, 2.5 equiv). The reaction was warmed to -40° C. and stirred for 2.5 h. To this mixture was added triisopropyl borate (3.2 mL, 2.5 equiv) and the reaction was allowed to warm to room temperature and stirred overnight. The next day the reaction was quenched with 2N HCl (3 mL) and stirred for 2 h. The solvent was removed and the residue was extracted with EtOAc and washed with H 2 O and brine. The organic was dried over anhydrous MgSO 4 and concentrated in vacuo to afford the titled compound. Rf=0.51 (1:1 EtOAc/Hex).
Step B: Preparation of 5-butyl-3-[(4-hydroxymethyl)phenyl]-2-(N-t-butylaminosulfonyl)thiophene
To a solution of the product of step A (3.2 g, 9.94 mmol) in toluene (60 mL) and 1N NaOH (17 mL, 2 equiv) was added 4-bromobenzyl alcohol (4.85 g, 3 equiv) in EtOH (15 mL). To this mixture was added Pd(PPh 3 ) 4 (300 mg, 3 mol%) and the reaction was stirred at reflux for 4 h. The reaction mixture was cooled to room temperature and extracted with EtOAc. The organic was washed with H 2 O and brine and dried over anhydrous MgSO 4 and concentrated in vacuo. The titled compound, Rf=0.21 (2:1 Hex/EtOAc), was purified by flash chromatography eluting with 2:1 Hex/EtOAc.
Step C: Preparation of 5-butyl-3-[(4-bromomethyl)phenyl]-2-(t-butylsulfonamido)thiophene
To a solution of the product of step B (309 mg, 0.81 mmol) in dry CCl 4 (2 mL) and CH 2 Cl 2 (2.5 mL) was added PBr 3 (0.06 mL). After stirring for 30 min the solvent was removed and the reaction mixture was concentrated several times from CCl 4 and CH 2 Cl 2 . The titled product, Rf=0.56 (2:2 Hex/EtOAc), was purified by flash chromatography eluting with 10:1 Hex/EtOAc.
Step D: Preparation of 5,7-dimethyl-2-ethyl-3-[[4-[2-(N-t-butylaminosulfonyl)-5-butyl-3-thienyl]phenyl]methyl]-imidazo[4,5-b]pyridine
To a solution of 5,7-dimethyl-2-ethylimidazo[4,5-b] pyridine (163 mg. 0.93 mmol) in dry DMF (2 mL) was added 60% NaH (41 mg). After stirring at room temperature for 45 min, a solution of the product of step C (276 mg, 0.621 mmol) in DMF (2 mL) was added and the reaction was stirred overnight. The next day the reaction was quenched with sat'd NH 4 Cl soln and the DMF was removed in vacuo. The residue was extracted into EtOAc and the organic was washed with H 2 O and brine and dried over anhydrous MgSO 4 . The titled compound, Rf=0.35 (1:2 Hex/EtOAc), was purified by flash chromatography eluting with 2:1 to 1:2 Hex/EtOAc.
1 H NMR (200 MHz, CDCl 3 ) ε0.93 (t, 3H), 0.96 (s, 9H), 1.32 (t, 3H), 1.38 (m, 2H), 1.68 (m, 2H), 2.60 (s, 3H), 2.66 (s, 3H), 2.82 (comp m, 4H), 4.02 (s, 1H), 5.52 (s, 2H), 6.72 (s, 1H), 6.94 (s, 1H), 7.22 (d, 2H), 7.53 (d, 2H).
Step E: Preparation of 5,7-dimethyl-2-ethyl-3-[[4-[2-(aminosulfonyl)-5-butyl-3-thienyl]phenyl]methyl]imidazo[4,5-b]pyridine
To a mixture of the product of step D (215 mg, 0.40 mmol) and anisole (3 drops) was added TFA (3 mL). After standing at room temperature overnight, the solvent was removed and the residue was dissolved in EtOAc and washed with 2N Na 2 CO 3 and brine. The organic was dried over MgSO 4 and concentrated in vacuo to provide the titled compound, Rf=0.31 (20:1 CH 2 Cl 2 /MeOH).
Step F: Preparation of 5,7-dimethyl-2-ethyl-3-[[4-[2-[(butyloxycarbonyl)aminosulfonyl]- 5-butyl-3 -thienyl]phenyl ]methyl]-imidazo[[4,5 -b ]pyridine
To a solution of the product of step E (26.3 mg, 0.055 mmol) in dry pyridine (0.75 mL) was added a catalytic amount of 4-pyrrolidinopyridine and butylchloroformate (0.07 mL, 10 equiv). After stirring overnight the reaction was quenched with MeOH and the solvent was removed in vacuo. The residue was dissolved in EtOAc and washed with 10% citric acid, H 2 O and brine. The organic was dried over MgSO 4 and concentrated in vacuo. The titled compound, Rf= 0.63 (40:10:1 CH 2 Cl 2 /MeOH/NH 4 OH), was purified by flash chromatography eluting with 80:10:1 CH 2 Cl 2 /MeOH/NH 4 OH. 1 H NMR (400 MHz, CD 3 OD) ε0.83 (t, 3H), 0.94 (t, 3H), 1.21 (m, 2H), 1.31 (t, 3H), 1.42 (comp m, 4H), 1.68 (m, 2H), 2.57 (s, 3H), 2.60 (s, 3H), 2.82 (t, 2H), 2.86 (q, 2H), 3.87 (t, 2H), 5.58 (s, 2H), 6.81 (s, 1H), 7.02 (s, 1H), 7.14 (d, 2H), 7.50 (d, 2H). | This invention relates to compounds represented by formula I: ##STR1## which are agonists of angiotensin II. The invention is also concerned with the use of aforementioned agonists in the treatment of states meditated by angiotensin. | 2 |
FIELD OF THE INVENTION
The present invention relates generally to gas guns and, more particularly, to gas guns having a precisely timed firing of a prepressurized projectile. This invention was made with government support under Contract No. W-7405-ENG-36 awarded by the U.S. Department of Energy to The Regents to the University of California. The government has certain rights in the invention.
BACKGROUND OF THE INVENTION
Dynamic shock experiments often require projectile impact to produce conditions of interest. Examples are studies of shock initiation of explosives, the equations of state of various materials, and wave interactions. Diagnostic devices used in such studies include asynchronous framing cameras, electronic cameras, pressure gauges, shock pins, and velocity interferometers. For these devices, when the projectile reaches a predetermined position, recording equipment such as transient digitizers, flash units, and laser pulses are triggered. Thus, the reference time is tied to the projectile location, once it has reached a steady velocity.
This timing arrangement is satisfactory if the diagnostic devices can be triggered at any time. For example, an asynchronous framing camera uses a rotating mirror and a continuous film track and therefore it is in a continuous ready state. All that is needed is a light flash of proper pulse length and intensity which can arrive at any time. Similarly, a transient digitizer is always ready to acquire data whenever the appropriate trigger is provided.
Some diagnostic devices are not always in the ready state; they are designed to generate the trigger at specific times when they are available to record data. For example, synchronous framing cameras use a rotating mirror, but have a film track that proceeds only part of the way around the circumference. These cameras send a synchronous pulse when the mirror is in a predetermined position, and recordable events in the experiment must be synchronized to this condition.
High pressure gas guns are commonly employed to accelerate projectiles for experiments which include impact studies and weapons uses. Conventional gas guns include a projectile which is located in the breech of the gun and a mechanism which triggers the release of a gas which impinges on the projectile and causes it to move out of the breech and down the barrel of the gun. The variable delay (0.5-10 ms) between gas release and the generation of sufficient force to move the projectile makes these gas guns high jitter devices, i.e., devices with low precision timing of the firing of a projectile. Due to this high jitter, gas guns have only been used with asynchronous diagnostics.
Several designs of gas guns are known. U.S. Pat. No. 4,747,350 for "Hollow Charge" which is issued to A. Szecket on May 31, 1988 describes a gun design which employs a disc to separate the barrel of the gas gun from a pressurized gas chamber. Upon reaching a critical pressure, the disc ruptures releasing the gas into the barrel to move the projectile. Similarly, U.S. Pat. No. 5,365,913 for "Rupture Disc Gas Launcher" issued to G. L. Walton on Nov. 22, 1994 describes a rupture disc placed between a compressed gas and a launcher tube in a gas launcher. The operator increases the pressure in the pressure chamber until it exceeds the rupture threshold of the disc, whereupon the disc ruptures and the gas escapes from the compressed gas chamber past the ruptured disc and pushes the projectile out of the launch tube.
U.S. Pat. No. 5,303,633 for "Shock Compression Jet Gun" issued to M. J. Guthrie et al. on Apr. 19, 1994 describes a chamber containing an explosive charge, a gas (or a substance that generates gas upon detonation of the explosive charge), and a barrier separating the charge from the gas. A diaphragm separates the chamber from one end of an expansion nozzle. The other end of the nozzle is attached to a coaxial tube containing a projectile. The projectile may have a band providing a seal with the tube. Upon detonation of the explosive charge, gas in the chamber pressurizes the chamber, ruptures the diaphragm, is accelerated as it moves through the expansion chamber, and moves the projectile.
U.S. Pat. No. 3,597,969 for "Dynamic Tester For Projectile Components" issued to H. D. Curchack on Aug. 10, 1971 describes an automated dynamic tester for projectile components. FIG. 1 of Curchack shows a grooved projectile housed within the midsection of a closed chamber called the acceleration gun. The aft region of the chamber is at atmospheric pressure while the forward region of the chamber is under vacuum. A pin inserted into the projectile groove prevents it from moving. When the pressure of the forward chamber exceeds a predetermined value, a valve withdraws the pin from the projectile groove to free the projectile. Since Curchack requires a vacuum, the projectile must pass through a diaphragm which enables the chamber to be evacuated. Curchack does not teach the use of high pressure to move a projectile, nor an open gun barrel. Curchack also does not teach pneumatic means for withdrawing the pin from the groove in the projectile.
Low jitter devices require precisely timed projectile firing; electrically actuated mechanical devices such as solenoids cannot be employed because they have unacceptable inherent variability in timing.
In view of the need for a more precisely timed gas gun, an object of the present invention is to provide a gas gun having low jitter.
Additional objects, advantages and novel features of the invention will be set forth in part in the description which follows, and in part will become apparent to those skilled in the art upon examination of the following or may be learned by practice of the invention. The objects and advantages of the invention may be realized and attained by means of the instrumentalities and combinations particularly pointed out in the appended claims.
SUMMARY OF THE INVENTION
To achieve the foregoing and other objects, and in accordance with the purposes of the present invention, as embodied and broadly described herein, the gas gun having low jitter hereof includes a barrel having an open end, a closed end, and a bore, a projectile having a circumferential recess and adapted to move within the bore of the barrel and provide a substantially gas tight seal therewith, a pin capable of being inserted into the recess of the projectile for restraining the projectile, means for applying gas pressure between the closed end of the barrel and the projectile, and a pneumatic means for rapidly removing the restraining pin from the recess of the projectile. Benefits of the present invention include the controlled release of a projectile.
BRIEF DESCRIPTION OF THE DRAWINGS
The accompanying drawings, which are incorporated in and form a part of the specification, illustrate embodiments of the present invention and, together with the description, serve to explain the principles of the invention.
In the Figures:
FIG. 1a shows a side view of the apparatus of the present invention showing the restraint of a projectile having a circumferential recess, while FIG. 1b shows the restraint of a projectile having a bevel in its forward end.
FIG. 2a shows the means for restraining and disengaging the pin which holds the projectile in place, while FIG. 2b shows a side view of the complete apparatus.
DETAILED DESCRIPTION OF THE INVENTION
Briefly, the present invention includes a gas gun having a projectile restrained under static gas pressure by a pin. Turning now to the drawings, similar or identical structure is labeled by identical call-outs. FIG. 1a shows one embodiment of the invention. Gas gun 10 includes body 12 with barrel 14 having open end 16 and bore 18 into which is placed projectile 20 having a circumferential recess 22. Deformable disc 24 is attached to base 25 of projectile 20 and makes a substantially gas tight seal with bore 18. For some experiments, in place of deformable disc 24, an o-ring was placed in a groove cut into the projectile 20 to provide a seal with the barrel. Disc 24, inner wall of body 12, and flange 26 define chamber 28 which is pressurized by pressurization means 27. Projectile 20 is restrained from moving in response to gas pressure from chamber 28 by restraining pin 32 inserted into recess 22. Restraining pin 32 is held in place by restraining and disengaging means 33.
FIG. 1b illustrates another embodiment of the invention utilizing beveled projectile 21. Projectile 21 is restrained by pin 32 making contact with bevel 23.
FIG. 2a shows details of pin restraining and disengaging means 33, which includes piston 34 housed within pressurized chamber 42 and making a substantially gas tight seal therewith by o-ring 36 and o-ring 40. Restraining pin 32 is attached to piston 34. Chamber 42 may be pressurized by pressurization means 43. Piston head 44 is connected to one end of breakable rod 48 by rod mount 46. The other end of breakable rod 48 is connected to flange 52 with rod mount 50. Flange 52 is connected to body 12 of FIG. 1a and 1b. Explosive 54 is near, or preferably in contact with breakable rod 48. Detonation means 60 is used to detonate explosive 54.
FIG. 2b illustrates the completed assembly of the embodiment illustrated in FIG. 1a, showing the relationship among restraining and disengaging means 33, restraining pin 32, and projectile 20. Projectile 20 is placed in breech 19 of gun 10. Deformable disc 24 was a plastic disc for the Example which follows. Restraining pin 32 is attached to piston 34. Piston wall 35, bore wall 41, o-ring 36 and o-ring 40 define chamber 42 which may be pressurized with pressurization means 43. When piston 34 is in place, o-ring 40 seals against wall 41 and restraining pin 32 fits into recess 22 of projectile 20. When flange 52 is attached to body 12, chamber 42 is pressurized by pressurization means 43, and chamber 28 is pressurized by means 27, pin 32 remains seated in recess 22 of projectile 20, thereby restraining it. Explosive 54 is mounted with detonator mount 56 such that explosive 54 is placed near or preferably in contact with breakable rod 48. Breakable rod 48 was a glass rod in the example below. The explosive 54 used in the Example was a Reynolds RP3 explosive detonator. At a desired time, detonation means 60 actuates explosive 54 which destroys rod 48, thereby allowing piston 34 to move in response to pressure within chamber 42 causing pin 32, which is attached to piston 34, to release projectile 20.
A major source of timing variability in conventional gas guns arises from delays in pressurization of the projectile. Electrically operated mechanical devices such as solenoids which have inherent timing variability in the millisecond to tens of milliseconds range are unacceptable for achieving low jitter. In the present invention, there is no delay due to initial buildup of pressure at base 25 for either projectile 20 or 21 because they are under constant high gas pressure.
Calculations using the equation below demonstrate that projectile 20 does not force pin 32 out of its way as it exits the breech 19. In contrast, pin 32 moves out of recess 22 of projectile 20 faster than projectile moves out of the breech 19. The ratio of the accelerations for the pin and the projectile is given by the following relationship: ##EQU1##
In the above equation, a xpin /a xproj is the ratio of the x-components of the acceleration of pin 32 to projectile 20. The angle θ describes the angle that pin 32 makes with bore 18. The apparatus was designed with θ=45 degrees. Also for the apparatus designed, A pin /A proj , the ratio of pin surface area to projectile surface area, is 1.14. The ratio of the projectile mass to the combined mass of pin 32, piston 34, o-ring 36, and mount 46 (which must all move as pin 32 exits recess 22 of projectile 20), m proj /m comb , is 2.21. Substituting the values for the above ratios and angle and further assuming no significant contribution from friction, the ratio a xpin /a xproj is 1.78; pin 32 acceleration is 1.78 times greater than projectile 20 acceleration. Therefore, when glass rod 48 breaks, pin 32 is not pushed out of recess 22 by projectile 20. The faster initial pin movement reduces potential delay caused by projectile 20 having to force the pin 32 out of the way as it exits the breech. Therefore, initial pressurization of the chamber 42 is essential in reducing the jitter of the invention.
EXAMPLE
The gas gun was designed to impart a velocity of 100-200 m/s to a projectile. The steel body of the gun was 54 cm long with a main bore diameter of 0.953 cm, and a gas chamber volume behind the projectile base of 50 cm 3 . Substantially larger velocities may be obtained by lengthening the gun barrel. Larger gas chambers may be employed to reduce operating pressures, however high chamber pressures are essential to achieve low jitter. The cylindrical projectile used was made of brass and had a circumferential recess as shown in FIG. 1a. It weighed 10 g and had a diameter 0.025 mm less than the diameter of the bore to reduce static and sliding friction. The gun was pressure rated at 8.3 MPa (megapascals).
The results of eleven experiments conducted with four different starting gas pressures using helium gas are given in the Table. The projectile location was determined with an argon ion laser. The laser beam was first split into two beams that intersected the projectile flight path at chosen positions. The beams were then recombined and imaged onto a silicon photodiode. Four separate times were recorded corresponding to the projectile face intersecting each beam (t 1 and t 3 ) and the exit of the projectile from each beam (t 2 and t 4 ). Differences between times t 1 and t 3 and between times t 2 and t 4 were averaged, and these times were then used to calculate the velocity for that experiment. The average projectile velocities for experiments conducted with the same initial gas pressure are shown.
TABLE______________________________________ Initial Pressure Barrel Transit Time Exit Velocity# Expts (MPa) (ms) (m/s)______________________________________3 6.895 5.286 181.74 4.137 7.751 139.22 2.758 9.745 114.22 1.379 15.44 79.4______________________________________
The barrel transit time is the time required for the projectile to travel through the main bore starting from rest. The barrel transit time ranges were very narrow, indicating a low jitter apparatus. At 6.895 MPa, the largest transit time difference, i.e. the jitter, for the 3 experiments was 41.2 μs, and for the 4 experiments at 4.137 MPa it was 58 μs. Thus, the jitter of the present invention is much smaller than that of typical gas guns, which have jitter of 0.5-10 ms.
The foregoing description of the invention has been presented for purposes of illustration and description and is not intended to be exhaustive or to limit the invention to the precise form disclosed, and obviously many modifications and variations are possible in light of the above teaching.
The embodiments were chosen and described in order to best explain the principles of the invention and its practical application to thereby enable others skilled in the art to best utilize the invention in various embodiments and with various modifications as are suited to the particular use contemplated. It is intended that the scope of the invention be defined by the claims appended hereto. | Gas gun with reduced timing jitter. A gas gun having a prepressurized projectile held in place with a glass rod in compression is described. The glass rod is destroyed with an explosive at a precise time which allows a restraining pin to be moved and free the projectile. | 5 |
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention relates to a method and apparatus for finishing textile products, and more particularly, to a method and apparatus for tip shearing tufted carpet utilizing an embossed surface below the backing which extends portions of the carpet closer to the cutting heads thereby cutting a pattern into the carpet which inversely corresponds with the extended portions of the embossed surface.
[0003] 2. Brief Description of Related Art
[0004] One method of finishing tufted carpet is to tip shear the loop ends to a uniform height. U.S. Pat. No. 4,323,612, which issued in 1982, discusses carpets finished in this manner.
[0005] The traditional method of tip shearing carpets involves running tufted carpet over a smooth roller where the roller contacts the polypropylene backing on the bottom of the carpet. The tufted loops are then cut to a uniform height utilizing a cutter having one or more blades which cuts the tufted loops to a uniform height relative to the back of the polypropylene layer on the back of a carpet since the blades of the cutter are a fixed distance from the roller. The greater a distance the tips of the pile extend from the backing, the greater amount is sheared.
[0006] The tip-shearing of carpet is utilized to provide a visual effect since the sheared ends provide a different visual effect than non-sheared ends. It has been discovered that the more material which is sheared away (i.e., the shorter lengths the carpet tufts are cut to extend from the backing), the darker most carpets become. It has also been discovered that loops are more durable and take wear better than sheared loops.
[0007] In some applications, it has been found that carpet may be tufted to high and low loops with the high loops resembling a design. The high loops may then be tip sheared to create a different effect than if they were allowed to remain as loops with the low loops not being cut in this process. While this technique produces an attractive carpet design, the sheared high loops extend a distance above the non-sheared low loops. Accordingly the sheared high loops take the brunt of the wear. Accordingly a need exists for a pattern to be cut into a carpet where the cut pattern extends a distance below the remaining loops.
[0008] U.S. Pat. No. 6,035,749 discloses a method of patterned shearing of pile fabrics which effectively utilizes compressed air to provide a particular pattern when utilized in conjunction with an otherwise uniform cutting and severing apparatus. While this reference teaches an excellent way of producing patterns in pile fabrics, it requires the addition of compressed air and jets to be placed proximate to the cutter assembly. This would require retrofitting existing tip shearing cutters with compressed air capability, jets and a controller for the jets.
[0009] Accordingly, a need exists to produce a design in carpets without necessarily requiring retrofilling and/or providing compressed air capability.
SUMMARY OF THE INVENTION
[0010] A need exists to be able to utilize existing tip shearing cutter equipment with a simple modification and/or addition to provide a patterned visual effect in the top surface of a pile fabric so that the finish fabric has a plurality of heights as measured from the back of the polypropylene backing.
[0011] Another need exists for tip-shearing carpet to provide a visual effect which is recessed relative to surrounding carpet portions.
[0012] Another need exists for selectively tip shearing carpet to at least two depths utilizing an otherwise uniform cutting shearing apparatus.
[0013] Another need exists to selectively elevate portions of pile fabric relative of non-selected portions to assist in providing a desired multi-height pattern when the elevated carpet portions contact the cutting blade or blades.
[0014] Accordingly, an embossed surface is positioned below the backing of the carpet during the shearing process. The embossed surface has raised portions which elevate portions of the carpet closer to the cutter of the tip shearing machine. These elevated portions are cut to a deeper depth than surrounding carpet portions. Accordingly, the cut pattern is inversely cut in the pile fabric relative to the embossed surface. This technique and apparatus is believed to result in a longer wearing carpet product.
BRIEF DESCRIPTION OF THE DRAWINGS
[0015] The particular features and advantages of the invention as well as other objects will become apparent from the following description taken in connection with the accompanying drawings in which:
[0016] FIG. 1 shows a prior art tip shearing apparatus;
[0017] FIG. 2 shows a first embodiment of a tip shearing apparatus of the present invention;
[0018] FIG. 3 shows a carpet section produced using the tip shearing apparatus of FIG. 2 ;
[0019] FIG. 4 shows a cross section of carpet taken along the line A-A of FIG. 3 ; and
[0020] FIG. 5 shows a side elevational view of an alternatively preferred embodiment for an embossed surface for use with the cutter of FIG. 2 .
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0021] Accordingly, FIG. 1 shows a portion of a prior art tip shearing mill 10 having a cutter 12 and a smooth roller 14 . As carpet 16 is passed intermediate the cutter 12 and the roller 14 , the tips 16 , or ends, are sheared to a uniform height as measured from the smooth cylindrical exterior surface 17 of the roller 14 . As shown in FIG. 1 , a high pile 18 height has been tufted to create a cross pattern which extends a distance above the lower pile 20 . After shearing, the high pile loops will be cut, but preferably not down as far as the top of the low pile 20 . This is known in the art to create a pattern. However, a disadvantage of this process is that the sheared or cut pile design (formerly high pile 20 ) is not as durable as the lower loops. Thus some designs have been found to wear disproportionately faster than the rest of the carpet since they bear the traffic as they extend a distance above the lower pile height.
[0022] FIG. 2 shows a tip shearing mill 30 of the preferred embodiment. The mill includes a shearing apparatus, such as a cutter 32 , and an embossed surface 34 on a roller 36 . The embossed surface 34 is shown attached to the roller 36 and having three distinct designs 38 , 40 , 42 , but as shown in and described relative to FIG. 5 , other embossed surfaces may be utilized with or without a roller 36 . Furthermore, the one or more designs 38 , 40 , 42 are illustrative in nature and could have any particular shape desired utilized using the technology described herein. As shown in FIG. 2 , the designs 38 , 40 , 42 have elevated surfaces 39 , 41 , 43 spaced a distance above unelevated roller surface 45 .
[0023] FIG. 3 shows a carpet section 44 which has been run through the mill 30 . Notice that the design of the embossed surface 34 is now apparent on the carpet 44 . However, as shown in FIG. 4 , the designs 38 , 40 , 42 have been cut into the carpet 44 . For instance, suppose that the carpet 44 is formed of a uniform pile height. As reflected by FIG. 4 , as the carpet 44 passes over the embossed surface 34 , the portions which now have the design are elevated a greater distance, i.e., moved closer to the cutter 32 , so that the blade, or blades, of the cutter 32 cut more material from the carpet where the embossed surface 34 pushes the carpet closer to the cutter 32 , even though the cutter 32 is cutting at a uniform height relative to the roller 36 . This results in the embossed surface 34 effectively being cut into the carpet 44 as shown in FIG. 4 . In fact, the depth of recessions 47 , 48 , 49 approximately corresponds with the height of the elevated surfaces 39 , 41 , 43 relative to the unelevated surface 45 .
[0024] Embossed surfaces 34 for may take a variety of forms. As shown in FIG. 2 , a roller 36 may be machined or otherwise constructed so that designs 38 , 40 , 42 , or other ornamentation extend a distance above an adjacent exterior and otherwise smooth cylindrical portion of the roller such as unelevated roller surface 45 . The designs 38 , 42 may perpendicularly extend a predetermined distance from the unelevated surface 45 and/or extend a variety of distances gradually as shown by design 40 .
[0025] Embossed surfaces 34 may be created on a roller 36 as illustrated in FIG. 2 or may be created in sheet form as shown in FIG. 5 . FIG. 5 shows a continuous loop 50 having an embossed surface 34 thereon which could be utilized with the cutter 32 of FIG. 2 . Alternatively a sheet segment 52 such as shown intermediate B-B and C-C in FIG. 5 may be fed along with carpet across the smooth roller 14 shown in FIG. 1 or other structure to achieve the desired pattern. The sheet 50 need not be continuous as illustrated, but the continuous sheet 50 is believed to be a convenient structure to utilize, especially for a repeating pattern.
[0026] A method of utilizing the apparatus, or mill 30 , involves directing carpet 44 intermediate the embossed surface 34 and the cutter 32 , having the cutter cut at a uniform height and thereby produce a design in the carpet 44 , or other pile fabric, inversely corresponding to the design of the embossed surface.
[0027] As shown in FIG. 2 , at least one of the embossed surface 34 and or cutter 32 is moveable relative to the other so that the desired amount of cutting may take place. Some carpets may have longer pile height than others, some may have thicker backing, and the ability to adjust the predetermined distance from the cutter to the embossed surface and/or roller, if utilized, is believed to be advantageous.
[0028] Numerous alterations of the structure herein disclosed will suggest themselves to those skilled in the art. However, it is to be understood that the present disclosure relates to the preferred embodiment of the invention which is for purposes of illustration only and not to be construed as a limitation of the invention. All such modifications which do not depart from the spirit of the invention are intended to be included within the scope of the appended claims. | An embossed surface is positioned opposite a pile fabric from a tip shearing apparatus. As the blades of the tip shearing apparatus contact the carpet, the embossed surface selectively elevates selected portions of carpet relative to unselected portions so that a design corresponding to the design of the embossed surface is inversely cut into the carpet. | 3 |
BACKGROUND OF THE INVENTION
The present invention relates to a device for connecting a first and a second part, comprising first and second housings of common axis formed respectively in these first and second parts, as also a key inserted axially into the first housing with a relatively small clearance and into the second housing with a relatively large clearance.
Devices of this type have been used for a very long time in engineering and in all fields of industry.
One particular example thereof is given by Patent U.S. Pat. No. 4,936,422 which relates to a disk-brake with sliding caliper and with single post, and which illustrates the preferred field of application of the present invention.
When it is a question of locking two parts to one another such as the yoke and the sliding caliper of a disk-brake, it is in fact necessary, because of production tolerances, to provide for the key to enter one of the two parts with a relatively large clearance, failing which assembly risks being impossible.
Nevertheless in certain applications, and in particular in the case of brakes also assembled and subjected to extreme conditions of use, the clearance between the key and the second part, therefore between the two parts, is productive of noise and creates a risk of premature wear resulting, at substantial accelerations in alternate directions, from a hammering of the two parts against one another.
The object of the present invention is precisely to avoid this process and to eliminate the effects for which it is responsible.
SUMMARY OF THE INVENTION
To this end, the device of the invention is essentially characterized in that the second housing and the key adopting at least partially the form of cylinders with non-circular bases each of which has different minimal and maximal diameters, the diameters of the second housing being greater than the corresponding diameters of the key and the maximal diameter of the latter being greater than the minimal diameter of the second housing, and in that this device further comprises a retaining member, resting against one of the two parts and exerting on the key a resilient torsional torque about said common axis, tending to align the maximal diameter of the key and the minimal diameter of the second housing.
In the case where the first and second parts are constituted respectively by the yoke and the caliper of a sliding caliper disk-brake, the retaining member is preferably constituted by a wire spring secured to the key and to the yoke respectively at first and second attachment points spaced apart from one another by a portion of length of this wire, and this portion of length extends at least partially in a direction different from that of said common axis so as to be subjected to a flexion during a sliding of the caliper resulting from a braking action, and so as thus to be capable of bringing the latter back at the end of this action.
According to one embodiment which is easy to use, the first attachment point is obtained by inserting the wire spring into a transverse bore made in the key.
If the wire spring is angled at the exit from the transverse bore at such an angle that the sliding of the caliper produces a rotation of the wire spring in the bore, then the wire spring is advantageously pressed onto the yoke at a point of rotation situated, along the length of this wire, between the first and second attachment points, and the second attachment point is situated apart from the plane formed by said common axis and said point of rotation.
DESCRIPTION OF THE DRAWINGS
The invention will now be described by way of example with reference to the accompanying drawings in which:
FIG. 1 is a plan view of a sliding caliper disk-brake using a device according to the invention;
FIG. 2 is a front view of the brake of FIG. 1;
FIG. 3 is a detail view in cross-section along line III--III of FIG. 1; and
FIG. 4 is a view similar to that of FIG. 3, drawn to an enlarged scale and along a slightly different sectional plane, and showing a key of cross-section also slightly different.
DESCRIPTION OF THE INVENTION
The disk-brake shown in FIGS. 1 and 2 is of the type comprising a yoke 1 and a caliper 2 slideably mounted on this yoke by means of an axial post 3.
A hydraulic brake actuator 4, integral with the caliper 2 is capable of applying onto a disk (not shown), secured to a wheel of a vehicle to be braked, two friction members 5 and 6 mounted on the brake by means of support plates 5a and 6a respectively.
The yoke 1 and the caliper 2, which are capable of turning with respect to one another about the hinge-forming post 3, are locked to one another in rotation by means of a key 7 engaged along an axis 8 in at least one housing 9 of the yoke 1 and a housing 10 of the caliper 2.
Whereas the clearance of the key 7 in the first housing 9 is minute, the clearance of this key in the housing 10 of the caliper is relatively large so as, in particular, to take up the production tolerances of the brake and its deformations under stress.
The object of the invention is in particular to prevent the necessarily large clearance between the key 7 and the housing 10 from becoming, in extreme conditions, a source of noise and a cause of wear.
The means used by the invention in order to solve this problem are shown in specific manner by FIGS. 3 and 4.
More precisely, the second housing 10 and the key adopt, at least in their mutual vicinity, the shape of cylinders with non-circular bases, each of which has different minimal and maximal diameters.
In other words, not only does their cross-section adopt a non-circular shape, but in addition two parallel straight lines tangent to this cross-section have between them a separation which varies as a function of their direction.
Because of this, "minimal diameter" here means, for each member in question (namely the key 7 on the one hand and the housing 10 on the other hand), the minimal distance which these two parallel straight lines may have between them while remaining tangent to the cross-section of this member, associated with the direction taken by these two straight lines when they are at this distance from one another.
As will be easily understood, the definition of "maximal diameter" can be extrapolated from the preceding definition.
According to the invention, the minimal and maximal diameters of the second housing 10 are respectively greater than the minimal and maximal diameters of the key 7, but the maximal diameter of the latter is greater than the minimal diameter of the second housing 10.
As shown in FIGS. 1 and 3, the key 7 may for example adopt the shape of a cylinder of circular base modified by two parallel flats 7a and 7b, and the housing 10 may be of essentially rectangular shape and possibly open.
The device of the invention furthermore comprises a retaining member adopting for example the form of a wire spring 11 inserted into a transverse bore 7c of the key 7, the point of insertion constituting a first attachment point 11a for the wire spring 11.
This wire 11, which rests on the yoke at a second attachment point 11b, has the function of exerting on the key 7 a resilient torsional torque, indicated by the arrow C, about the common axis 8, tending to align the maximal diameter DM of the key 7 with the minimal diameter of the second housing, which has the direction of the width of the rectangle which is formed by the latter.
According to another major feature of the invention, the portion of the length of the wire 11 which separates the attachment points 11a and 11b extends at least partially in a direction different from that of the axis 8, so as to be capable of being subjected to a flexion during the sliding of the caliper 2 under the effect of a braking action, and so as thus to be capable of bringing the caliper back at least into the vicinity of its initial position after the end of the braking action.
As shown in FIGS. 3 and 4, the wire spring 11 is for example angled at the exit from the bore 7c and additionally rests (FIGS. 1 and 3) against a point of rotation 1a which is formed by a relief of the yoke 1 and is situated, along the length of the wire 11, between the first and second attachment points 11a, 11b.
In another respect, the wire spring 11 preferably engages the second attachment point 11b through the intermediary of a loop 11c, so that this second attachment point is situated apart from the plane passing through the axis 8 and the point of rotation 1a, which permits a slight action on the wire spring 11 in torsion and increases the capacity of this wire to bring the caliper back into position after a sliding on the post 3.
Lastly, as shown in FIG. 4, the key 7 may advantageously have a cross-section more developed than that of a segment of a circle and particularly a cross-section devoid of angular points. | A combination of a device connecting a yoke (1) and a caliper (2) of a sliding caliper disk-brake includes a key (7) engaged axially in housings of the yoke (1) and caliper (2). The key (7) and one of the housings (10) have non-circular cross-sections and the key (7) is acted upon resiliently by a wire spring (11) of the device so as to reduce the clearance with the housing (10). | 5 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to the use of a microbially-produced fermentation residue as a component in adhesives for wood products.
2. Description of the Prior Art
Over the last several decades renewable resources have contributed an increasing share of fuel and chemical production in developed countries. One of the largest of these contributors has been ethanol produced by fermentation and used as a gasoline additive. Commercial ethanol is produced almost exclusively by saccharification of starch (usually from corn) and subsequent fermentation of the sugars by Saccharomyces yeast. The development of fermentations based on cellulosic biomass, instead of on starch, has remained attractive because of the low cost and great abundance of cellulosic materials, either directly from biomass energy crops, or from agroforestry wastes (Lynd et al., Biotechnol. Prog. 15:777-793, 1999).
Though research on bioconversion of cellulosic materials to ethanol has largely focused on chemical or enzymatic hydrolysis of biomass with subsequent fermentation of sugars by yeast, the process is not economically viable for a variety of reasons (Lynd et al. 1999 supra). The chemical hydrolysis route suffers from a requirement for postprocessing (e.g., neutralization of the hydrolysate, the costly handling of waste products, and the removal or treatment of fermentation inhibitors formed during hydrolysis). The enzymatic route involves high costs associated with producing fungal enzyme with low inherent specific activities. A potential alternative route for cellulose bioconversion involves processes in which enzyme production, enzymatic hydrolysis and sugar fermentation occurs in a single bioreactor (Lynd et al. 1999 supra; Lynd et al., Microbiol. Molec. Biol. Revs. 66:506-577, 2002). There is little doubt that the economic viability of biomass conversion processes will ultimately depend on the marketability of co-products produced during the bioconversion process. This is implicit in the modern notion of a biorefinery that is envisioned to ultimately produce a suite of biologically-derived commercial products (Lynd et al. 1999 supra).
The ruminal cellulolytic bacterium Ruminococcus albus can ferment cellulose, some hemicelluloses (e.g., xylans and glucomannans) and pectin, to produce a mixture of ethanol, acetic acid, H 2 and CO 2 (Hungate, Academic Press, New York, N.Y., 1966; Pavlostathis et al., Appl. Environ. Microbiol. 54:2655-2659, 1988). A necessary prerequisite of the R. albus cellulose fermentation is adherence of the bacteria to cellulose, which is mediated by a variety of adhesins that include cellulose binding domains of cellulolytic enzymes; components of polycellulosomal organelles; pilin-like proteins and exopolysaccharide-containing glycocalyx materials (Miron et al., J. Dairy Sci. 84:1294-1309, 2001; Weimer, J. Dairy Sci. 79:1496-1502, 1996). The glycocalyx is relatively resistant to disruption by physical and chemical forces normally encountered by the organism in culture or in the rumen environment.
In unrelated work, the incorporation of natural products into chemical, industrial adhesive formulations has been explored (Loetscher, U.S. Pat. No. 1,959,433, 1934, Feigley, U.S. Pat. No. 2,868,743, 1959, Conner et al., J. Wood Chem. Technol. 6:591-613, 1986, Addition to phenol-formaldehyde (PF) resins of carbohydrates with large amounts of reducing end groups is known to result in loss of adhesive properties if the carbohydrate exceeds about 10 per cent of the weight of the PF resin (Feigley 1959 supra). By contrast, adhesive properties of PF resins are maintained upon addition of up to 30-50 per cent of the total adhesive weight of sucrose, methyl monosaccharides or sugar alcohols (Conner et al. 1986 supra).
Proteins of biological origin (e.g., blood or soybeans) were commonly used in the adhesives industry prior to the development of formaldehyde-based synthetic chemical adhesives. Neither these biological materials, nor most carbohydrates, are typically involved in adhesion in nature. However they can display adhesive properties when properly denatured, mixed with other materials, and cured under heat and pressure (Lambuth, Pizzi A., Mittal K. L., (eds) Handbook of Adhesive Technology, Marcel Dekker, New York, N.Y., pp. 259-282, 1994). The resulting mixed resins show acceptable strength under dry conditions, but often display reduced adhesive strength under wet or humid conditions (Lambuth 1994).
SUMMARY OF THE INVENTION
We have now invented an adhesive composition useful for producing wood products, the adhesive composition comprising a microbially-produced fermentation residue containing adherent microbial cells and glycocalyx. This residue finds particular application as a replacement for a significant amount of phenol-formaldehyde (PF) resin commonly used in the production of plywood and other wood products.
In accordance with this invention, it is an object of the invention to provide a novel adhesive material for use in the production of wood-based products.
It is a further object of this invention to provide a bioadhesive replacement for at least a portion of the PF resin currently used in lay-up of plywood and other glued wood products.
It is also an object of the invention to provide an industrial use for solid residues resulting from fermentative conversions of cellulosic substrates.
Other objects and advantages of this invention will become readily apparent from the ensuing description.
BRIEF DESCRIPTION OF THE FIGURES
FIG. 1A is a bar graph illustrating shear strength, and FIG. 1B is a bar graph illustrating wood failure percentage, for 3-ply aspen plywood panels prepared with adhesives (based on fermentation residue of microcrystalline cellulose) described in Table 3, tested under dry conditions. Numbers in parentheses indicate percentage of fermentation residue by weight in the adhesive formulation. Samples having different lower-case letters within treatments differ (P<0.05). Pooled standard error for shear strength=0.58 MPa. Pooled standard error for wood failure=16.9%.
FIG. 2A is a bar graph illustrating shear strength, and FIG. 2B is a bar graph illustrating wood failure percentage, for 3-ply aspen panels prepared with different adhesives (based on fermentation residue of microcrystalline cellulose), tested after vacuum/pressure/soak [VPS] treatment. Numbers in parentheses indicate percentage of fermentation residue by weight in the adhesive formulation. Samples having different lower-case letters within treatments differ (P<0.05). Pooled standard error for shear strength=0.46 MPa. Pooled standard error for wood failure=16.4%.
FIG. 3A is a bar graph comparing shear strength for 3-ply aspen plywood panels prepared with adhesives (based on fermentation residue of alfalfa fiber) tested under dry conditions with shear strength for similarly made panels after VPS treatment. 5778ext=phenol-formaldehyde plywood resin having 42% solids with added walnut shell flour and GLU-X in equal amounts by weight at a combined level of 30% of total solids; unalf30=gp5778 resin with unfermented alfalfa added (30% of total solids); raalf30=gp5778 resin with Ra7 lyophilized fermentation residue (LFR) of alfalfa added (30% total solids); raalf45=gp5778 resin with ground Ra7 LFR from Example 6 added (45% total solids); ctalf30=gp5778 resin with ground Ra7 LFR from Example 6 added (30% total solids); ctalf45 gp5778 resin with ground Ra7 LFR from Example 6 added (45% total solids).
FIG. 3B is a bar graph comparing wood failure for 3-ply aspen plywood panels prepared with adhesives (based on fermentation residue of alfalfa fiber) tested under dry conditions with wood failure for similarly made panels after VPS treatment. Legends are the same as for FIG. 3A .
DEPOSIT OF BIOLOGICAL MATERIAL
Ruminococcus albus strain 7 and Ruminococcus flavefaciens strain FD-1 were deposited on May 5, 2003, under the provisions of the Budapest Treaty in the Agricultural Research Culture Collection (NRRL) in Peoria, Ill., and have been assigned Accession Nos. NRRL B-30653 and NRRL B-30654, respectively.
DETAILED DESCRIPTION
The expression “fermentation residue” as used herein refers to the solid residue resulting from the fermentation of certain microbes that produce any one, or a combination of: adhesins that include cellulose binding domains of cellulolytic enzymes; components of polycellulosomal organelles; pilin-like proteins; and exopolysaccharide-containing glycocalyx materials.
The expression “glycocalyx material” as used herein refers to any network of polysaccharide- and/or protein-containing material extending outside of the cell.
Agricultural biomass is defined herein to mean any cellulosic or lignocellulosic plant material, especially waste material, including but not limited to, leaves and stalks of both woody and non-woody plants. The term “woody” is used herein both in the botanical sense to mean “comprising wood”; that is, composed of extensive xylem tissue as found in trees and shrubs, and also in the sense of “being woodlike”. Accordingly, “nonwoody” refers to materials lacking these characteristics.
Agricultural biomass from woody plants would include orchard prunnings, chaparral, mill waste (such as bark, chips, shavings, sawdust, and the like), urban wood waste (such as discarded lumber, wood pallets, crates, tree and brush trimmings, etc.), municipal waste (such as newspaper and discarded grocery produce), logging waste and forest thinnings (tree tops, limbs and cull material), short-rotation woody crops such as poplar and cottonwood, and industrial waste (such as wood pulp sludge).
The preponderance of biomass from non-woody plants is derived from monocotyledonous plants, and especially grassy species belonging to the family Gramineae. Of primary interest are gramineous agricultural residues; that is, the portion of grain-bearing plants that remain after harvesting the seed. Illustrative of such residues, without limitation thereto, are wheat straw, oat straw, rice straw, barley straw, rye straw, flax straw, sugar cane, corn stover, corn stalks, corn cobs, corn husks, and the like. Also included within this definition are grasses not conventionally cultivated for agricultural purposes, such as prairie grasses (e.g. big bluestem, little bluestem, Indian grass), gamagrass, and foxtail. Certain dicotyledonous plants, such as alfalfa ( Medicago sativa ) and other leguminous forage crops would also be useful as a source of fermentable biomass.
Other agricultural byproducts in the category of biomass include waste streams components from commercial processing of crop materials (such as sugar beet pulp, citrus fruit pulp, seed hulls, and the like), lawn clippings, seaweed, etc.
The starting material for use herein may also be an agricultural biomass hydrolysate. The term “agricultural biomass hydrolysate” or variations thereof is used herein to refer to any of the aforementioned biomass materials that have been pretreated with acid to solubilize the xylan and cellulose in the material and to release sugar monomers. The hydrolysate may have residual xylan or may have been treated to remove the xylan prior to the detoxification treatment described hereafter.
Any of the aforementioned biomass materials would be useful herein as substrates for production of the fermentation material as either a primary product or as a by-product, such as in conversion of the biomass to ethanol.
Organisms useful for producing a suitable fermentation residue from the aforementioned biomass materials in accordance with the invention include any that can be fermented under conditions that will yield a readily recoverable amount of the residue comprising an extracellular polymeric matrix for sticking to the cellulosic biomass substrate. Of particular interest is any strictly anaerobic cellulose-digesting bacterium that adheres to cellulose fibers via a thick, adherent glycocalyx material. Without limitation thereto, such organisms would include the ruminal cellulolytic bacteria such as Ruminococcus albus, R. flavefaciens and the like. Specific stains of Ruminococcus preferred for making the products of the invention include R. albus , strain 7, and R. flavefaciens , strains B34b and FD-1. Also of interest are Clostridium species, especially C. thermocellum . Two such strains that have indicated ability to produce glycocalyx material are ATCC 27405 and JW20. Also contemplated for use herein are cultures having all the identifying characteristics of the aforementioned strains.
Typically, the biomass fermentation with a ruminal cellulolytic bacterium will be conducted under anaerobic conditions on any suitable medium, such as a modified Dehority medium (MDM), described further in Example 1, below. Though it is possible to hasten the attainment of anaerobic conditions in the fermentation vessel prior to inoculation, such as by exposing the medium to strong light following addition of a chemical reducing agent, an anaerobic state is eventually reached during the fermentation. The fermentation would be conducted at a temperature within the range of about 35-42° C., preferably about 37-40° C. Typically, the cultivation will be conducted at a pH within the range of about 6.0-7.1, and preferably at a pH of 6.5-6.6. However, pH control is usually unnecessary. Occasional stirring or agitation of the culture will tend to facilitate complete colonization of the substrate by the cells, and thus production of the adhesins. The fermentation would typically be continued until the level of glycocalyx material production is optimized. With a 2% inoculum by volume, fermentation would be complete by 48 hours. At a lower inoculum rate (˜0.5% by volume) without stirring, it may be necessary to continue the fermentation for a period of 3 to 5 days. Clostridium species are cultivated under similar anaerobic conditions, though a suitable fermentation temperature is in the range of about 57-62° C., and optimally about 60° C.
Isolation of the fermentation residue is accomplished by separating the rather sticky sediment layer (containing glycocalyx, embedded cells, and residual substrate) from the liquid phase. The separation can be effected by any means known in the art, to include decanting, siphoning, screening, filtering, centrifugation and the like in order to remove the preponderance of the medium, undigested substrate and residual cells and to recover the residue containing the glycocalyx material. The recovered residue may optionally be washed and dried, such as on a belt drier to a free-flowing particulate material (e.g. to a moisture level of 15-20% by weight). Further purification of the recovered residue is optional, depending on the prospective end use application. It is desirable to obtain the highest surface:mass ratio in the glycocalyx material, at least to the point of practicality. To this end, it may be desired to further grind the particles recovered from the drying operation, such as in a Wiley mill, and then to screen the material to eliminate oversized particles. With most biomass materials as the starting substrate, it is expected that recovered product having a maximum particle size on the order of 0.5 mm would strike an optimum balance between the economics of production and adhesive performance. For many specialized applications, it may be desirable to employ an even smaller particle size, such as a maximum screen size of 0.1 mm, 0.05 mm, or even 0.01 mm. When in the dry state, the recovered glycocalyx-containing material is a free-flowing powder. When plasticized by water or similar solvent, the material becomes sufficiently deformable for making a bond.
Recovered fermentation residues having relatively high (greater than about 30% (glycocalyx material) may be used, by itself, as an adhesive. At lower levels of glycocalyx material, the recovered fermentation residues described above more typically will be added a component to conventional adhesives, as a partial replacement therefore. Typical water-borne adhesives for use herein include urea-formaldehyde, melamine-formaldehyde, melamine-urea-formaldehyde, melamine-modified urea-formaldehyde, phenol-formaldehyde, resorcinol-formaldehyde, phenol-resorcinol-formaldehyde, phenol-urea-formaldehyde, furan-phenol-formaldehyde, furan-phenol-resorcinol-formaldehyde, poly (vinyl acetate), ethylene vinyl acetate polymers, poly (vinyl alcohol), water-borne epoxies, and emulsion polymerized isocyanate; adhesives derived from acrylics, starch, tannin, lignin, and lignosulfonate; and also adhesives derived from proteins, such as soybean, blood, casein, animal bone, and animal hide. Of particular interest is the use of the residues in adhesive formulations in combination with phenol-formaldehyde (PF).
The residues can be added to conventional adhesives in large amounts of at least 15%, 20%, 30%, 50%, or even 75% by weight (dry basis) without significant loss of the adhesive properties of the resin, itself. In the context of the amount of fermentation residue that is applied between two surfaces as an adhesive, an “effective amount” is defined herein as that amount which will produce a stable bond between those surfaces for whatever purpose those surfaces are being bonded together. Thus, for example, an effective amount of fermentation residue between veneer layers or exterior grade plywood would be that amount which will bind those layers together to withstand conditions according to established industry standards. In the context of an amount of fermentation residue that is used as partial replacement of a chemical adhesive, such as PF resin, an “effective amount” is defined herein as an amount that will yield a formulation comprising both the fermentation residue and the chemical adhesive, wherein the formulation will produce a stable bond between surfaces to which the formulation is applied. Adhesive formulations contemplated herein would also include extenders and other additives as known in the adhesive art.
The adhesives of the invention would be useful in bonding multiple layers or pieces of wood or other lignocellulosic material to one another, such as in the production of plywood, particleboard, pressboard, flakeboard, chipboard, veneered products, etc. In the production of plywood, the adhesive is applied to veneer surfaces by any of a variety of methods, such as spraying, roll coating, knife coating, or curtain coating. Two or more of the veneers are then laid-up to form sheets of required thickness. The mats or sheets are then placed in a heated press and compressed to effect consolidation and curing of the materials into a board. In the production of the aforementioned composite materials, wood materials such as flakes, fibers, particles, wafers, strips or strands are blended or sprayed with the adhesive material to form a uniform mixture. The materials are thereafter formed into a loose mat, which is compressed between heated platens in order to permanently bond the products together. Conventional processes are generally carried out at temperatures in the range of about 120-225° C. in the presence of steam generated by intrinsic moisture contained in the wood materials.
The following examples are intended to further illustrate the invention, without any intent for the invention to be limited to the specific embodiments described therein.
All references disclosed herein or relied upon in whole or in part in the description of the invention are incorporated by reference in their entirety.
Example 1
Preparation of R. albus Fermentation Residues Containing Bioadhesive from Microcrystalline Cellulose
Preparation Procedure.
Ruminococcus albus (strain 7) and Ruminococcus flavefaciens (strains B34b and FD-1) were revived from 80° C. glycerol stocks, and were grown at 39° C. under a CO 2 atmosphere. The medium was a modified Dehority medium (MDM), which contained the following (per liter): 0.9 g KH 2 PO 4 , 3.2 g Na 2 CO 3 , 0.90 g NaCl, 0.73 g NH 4 Cl, 0.085 g MgCl 2 .6H 2 O, 0.066 g CaCl 2 .2H 2 O, 0.028 g MnCl 2 .4H 2 O, 0.02 g FeSO 4 .7H 2 O, 0.01 g ZnCl 2 , 0.002 g CoCl 2 .6H 2 O, 0.002 g resazurin, 0.5 g yeast extract, 1.0 g cysteine HCl, 10 ml of Schaefer's vitamin mixture (Schaefer et al., J. Dairy Sci. 63:1248-1263, 1980, but amended with 0.125 mg of tetrahydrofolic acid per liter of vitamin mix) and 0.067 ml each of isobutyric, 2-methylbutyric, n-valeric and isovaleric acids. For R. albus 7, the medium was also amended with 25 μM of 3-phenylpropanoic acid (PPA, Morrison et al., Appl. Environ. Microbiol. 56:3220-3222, 1990). Additional Na 2 CO 3 was added from a saturated solution to adjust the initial pH of the medium to 6.9. The medium contained 4 g Sigmacell 50 microcrystalline cellulose (SC50) as the sole fermentable carbohydrate.
Fermentations to produce the residues for adhesive testing were carried out in 45 l glass carboys containing 40 l of the above medium, wherein the cellulose was either SC50 (3 g/l) or long fibrous cellulose CF1 (Sigma, 4 g/l) (Table 1). The medium (without cellulose) was filter-sterilized into carboys that contained the cellulose and enough water to hydrate the solids. The carboys had been previously sterilized by autoclaving (121° C., 60 min). Carboys were warmed to 39° C., gassed with CO 2 and illuminated with a bright incandescent light (Fukushima et al., Anaerobe 8:29-34, 2002) until the medium was fully anaerobic. (as revealed by decolorization of the resazurin). Carboys were then inoculated with 200 ml of late exponential-phase, cellulose-grown culture, and were vigorously swirled once or twice daily to suspend the cellulose particles and facilitate their complete colonization by the cells. After 88 to 108 h of incubation, the liquid phase was removed by siphoning, and the rather sticky sediment layer (containing glycocalyx, embedded cells, and residual cellulose) was resuspended in a small volume of deionized water. The resuspended material was centrifuged at 15,000×g for 45 min, and the supernatant discarded. Centrifugation always resulted in a small amount (<5% by volume) of a grey-colored layer of cells that sedimented atop the yellow glycocalyx; this layer was removed by careful scraping with a stainless steel spatula. The pellet, which contained primarily residual cellulose along with variable amounts of glycocalyx material and adherent cells, was lyophilized; these materials are designated LFR (lyophilized fermentation residue). In one case, a portion of the pellet was incorporated into the adhesive formulation while still wet, for comparison to the lyophilized material; this material was designated WFR (wet fermentation residue)
Composition of Fermentation Residues.
Lyophilized fermentation residues were analyzed for protein and for alkali-soluble carbohydrate after treating ˜10 mg (weighed to 0.001 mg) of residue with 0.50 ml of 1 N NaOH at 70° C. for 1 h. Treated samples were neutralized by addition of 0.50 ml of 1 N HCl, and were centrifuged (12,000×g, 5 min). The supernatants were assayed for protein by the method of Bradford M M (Anal. Biochem. 72:248-254, 1976), using Coomassie Plus reagent (BioRad, Hercules, Calif.) with lysozyme as protein standard, and were assayed for alkali-soluble carbohydrate by the phenol-sulfuric acid method (Dubois et al., Anal. Chem. 28:350-356, 1956) with glucose as standard.
To remove cellular material for subsequent characterization of the glycocalyx, residues (1 g) were autoclaved (121° C., 45 min) in 100 ml of neutral detergent solution (Goering and Van Soest, Agricultural Handbook No. 379, Agricultural Research Service, United States Department of Agriculture, Washington, D.C., 1970). The solid residue was filtered onto 47 mm-diameter polycarbonate membranes (3 μm pore diameter; Poretics, Livermore, Calif.) and rinsed exhaustively with hot deionized water prior to lyophilization. Subsamples (10 mg) of the lyophilized neutral detergent fiber (NDF) were treated with 1 ml of 2 N trifluoroacetic acid at 120° C. for 1.5 h, dried under an air stream, resuspended in 1 ml of deionized water, and passed through Supelclean SAX anion exchange columns (Supelco, Bellefone, Pa.). Neutral sugars were determined by ion chromatography (Hatfield and Weimer, J. Sci. Food Agric. 69:185-196, 1995). The results of protein and carbohydrate analyses are reported in Table 2.
Example 2
Adhesive Preparation
R. albus Fermentation Residue from Microcrystalline Cellulose
The following adhesive sources were used for the construction of plywood panels: phenol formaldehyde (PF, 42% solids; Neste Resins Corp., Springfield, Oreg.); wet fermentation residue (WFR) from R. albus 7 fermentation as prepared in Example 1 (33% solids in water, never dried); and lyophilized fermentation residue (LFR) from four separate Ruminococcus fermentations as prepared in Example 1 (each mixed with water to 33% solids). The adhesives were formulated according to Table 3. When mixing the LPR and PF together, the LFR was initially mixed with water until smooth, and then the PF was added and mixed well. PF, when used without fermentation residue, was supplemented with GLU-X (The Robertson Corporation, Brownstown, Ind.), a wheat-derived protein and starch product commonly used as a glue extender.
Example 3
Plywood Panel Layup
R. albus Fermentation Residue from Microcrystalline Cellulose
Aspen veneer, 178×178×3 mm (7×7×⅛ inch) thick was conditioned to equilibrium moisture content at 27° C., 30% relative humidity (RH). Adhesive prepared as described in Example 2 was weighed onto veneers as required for the construction of three-ply panels and spread evenly across the veneer with a spatula. Veneer sheets were arranged in a cross-ply pattern (i.e., the wood grain in the middle sheet was oriented perpendicular to the grain of the outer sheets) and were pressed at 180° C. and 1.125 MPa (163 lb/in 2 ). The adhesives used, singly or in combination, along with pressing times, are shown in Table 3.
Example 4
Analysis of Adhesive Properties of Plywood Panels
R. albus Fermentation Residue from Microcrystalline Cellulose
Each three-ply panel as prepared in Example 3 was conditioned at 27° C., 30% RH for ˜1 to 2 weeks before cutting into twelve standard lap shear specimens as outlined in PS 1-95 (National Institute of Science and Technology 1995). Six specimens from each panel were tested for dry shear strength using a universal testing machine at a loading rate of 1 cm/min. The remaining six specimens from each panel were subjected to a standard VPS treatment (National Institute of Standards and Technology 1995, Washington, D.C.). A vacuum of 85 kPa (25 in. of Hg) was drawn on the specimens while in water and held for 30 min. The vacuum was broken and a pressure of 450 to 480 kPa (65-70 lb in −2 ) was applied to the specimens while still in water, and held for 30 min. Shear strength was determined on the wet specimens using a universal testing machine at a loading rate of 1 cm min −1 . Wood failure percentages were determined on the dry shear samples after testing and on wet shear specimens after testing and subsequent air drying using ASTM procedure D-5266-99 (American Society for Testing and Materials 1999, West Conshohocken, Pa.).
The shear strength for panels tested under dry conditions are illustrated in FIG. 1A . The wood failure results for panels tested under dry conditions are illustrated in FIG. 1B .
The shear strengths for panels tested after VPS treatment are illustrated in FIG. 2A . The wood failure results for panels tested after VPS treatment are illustrated in FIG. 2B .
Example 5
Preparation of R. albus Fermentation Residues Containing Bioadhesive from Alfalfa Fiber
Alfalfa fiber from a wet fractionation process was air-dried and prepared inside a heated (39° C.) room. Fifty grams of air-dried alfalfa fiber was placed inside a custom-made column bioreactor consisting of a vertically-oriented, 29.4 cm×7 cm polycarbonate tube. Each end of the tube was capped with a tightly-sealed fitting for connection to rubber tubing. The interior face of the fitting included a fine-screened (30 micrometer) nylon mesh screen to contain the alfalfa particles. The bed of alfalfa was held against the bottom fitting by a stainless steel weight having a central hole of about 3 mm diameter to permit passage of liquid and gas; a stainless steel mesh screen was placed between the alfalfa fiber and the weight to contain particles. The entire unit was autoclaved for 15 min at 15 lb/in 2 , after which Modified Dehority medium (MDM, 1.2 liters) was pumped into the reactor through a sterile filter, using a peristaltic pump. The reactor was gassed with a gentle stream of CO 2 during the pumping. The column reactor was inoculated through a separate port with 10 mL of a culture of Ruminococcus albus 7 (previously grown on MDM cellulose for 36-48 h). Culture medium was recirculated through the column reactor at a flow rate of approximately 2 mL per min. After 5 to 7 days, the residual solids (fermentation residue) in the column were removed (though the fermentation typically stabilized within 3 or 4 days), squeezed through paper towels reinforced with nylon thread, and freeze-dried.
Nine separate column reactor runs were made as described above. The average recovery of residue per run was 29.1 g. All of the residues were freeze-dried (except a small amount retained for compositional analysis) and were composited into a single batch for adhesives testing, either alone or in combination with phenol-formaldehyde residue.
Example 6
Large Scale Preparation of R. albus and C. thermocellum Fermentation Residues Containing Bioadhesive from Alfalfa
Preparation Procedure.
Cultures of R. albus 7 and C. thermocellum ATCC 27405 were revived from glycerol stocks at −80° C. and were grown as pure cultures in anaerobic test tubes under a CO 2 atmosphere in modified Dehority medium containing Sigmacell 50 microcrystalline cellulose as sole fermentable carbohydrate (see Example 1). The incubation temperatures for R. albus and C. thermocellum were 39° C. and 60° C., respectively. Cultures of both organisms were scaled to 4-10 L in glass carboys containing the same medium, but with ground alfalfa fiber replacing cellulose as substrate. The carboys were used to inoculate modified 380 L fermentors (Fermentation Design, working volume 300 L, inoculum volume ˜11 L). These fermentations were carried out for 50 h.
For both cultures, the fermentation residues were recovered by pumping the fermentor contents through a 30.5 cm (12-inch) Sperry plate-and-frame filter press fitted with 14 cellulose filter sheets (32 cm×32 cm×0.16 mm, grade 901 paper, BIF America). The filters were hand-scraped to remove the fermentation residue (containing residual fiber, glycocalyx and adherent bacterial cells), which was then freeze-dried. The lyophilized fermentation residue (LFR) was ground through a Wiley mill (0.5 mm screen) and used directly for adhesive formulations.
Example 7
Adhesive Preparation
R. albus and C. thermocellum Fermentation Residues Containing Bioadhesive from Alfalfa
The following adhesive sources, shown in Table 4, were used for the construction of plywood panels:
5778ext: phenol-formaldehyde plywood resin (Georgia-Pacific Resins, Inc., Decatur, Ga.) having 42% solids with added walnut shell flour and GLU-X (The Robertson Corporation, Brownstown, Ind.) at a combined level of 30% of total solids;
unalf30%: gp5778 resin with unfermented alfalfa added (30% of total solids);
alfRA30%: gp5778 resin with Ra7 lyophilized fermentation residue (LFR) of alfalfa added (30% total solids);
alfRA45%: gp5778 resin with ground Ra7 LFR from Example 6 added (45% total solids);
alfCT30%: gp5778 resin with ground Ra7 LFR from Example 6 added (30% total solids);
alfCT45%: gp5778 resin with ground Ra7 LFR from Example 6 added (45% total solids).
When mixing the LFR and resin together, the LFR was initially mixed with water until smooth, and then the resin was added and mixed well.
Example 8
Plywood Panel Layup
R. albus and C. thermocellum Fermentation Residues Containing Bioadhesive from Alfalfa
Aspen veneer, 178×178×3 mm (7×7×⅛ inch) thick was conditioned to equilibrium moisture content at 27° C., 30% relative humidity (RH). Adhesive prepared as described in Example 7 was weighed onto veneers at the rate of 7 g/glueline as required for the construction of three-ply panels and spread evenly across the veneer with a spatula. Veneer sheets were arranged in a cross-ply pattern (i.e., the wood grain in the middle sheet was oriented perpendicular to the grain of the outer sheets) and were pressed at 180° C. and 1.14 MPa (0.165 lb/in 2 ) for 5 min. The three-ply test panels were conditioned at 27° C. and 26% RH for 1 week. Thereafter, the panels were cut into lap-shear specimens, 82.5×25.4 mm. (3¼×1 in) and evaluated for wet and dry shear strength and wet and dry wood failure by procedures described in Example 4.
The shear strength for panels tested under dry conditions and after VPS treatment are illustrated in FIG. 3A . The wood failure results for panels tested under dry conditions and after VPS treatment are illustrated in FIG. 3B .
Example 9
Bonding Properties of Glycocalyx Material without Phenol-Formaldehyde Resin
To test bonding of glycocalyx material without phenol-formaldehyde, small 50.8×50.8 mm (2×2×⅜ in) specimens were made of coarse ground alfalfa, unfermented and fermented with R. albus 7. Seventeen grams of dry alfalfa plus 17 g water were mixed well and formed into a mat, then pressed to 9.5 mm (⅜ in) thick at 180° C. for 5 min. The Ra7 fermented alfalfa specimen bonded together, but the unfermented alfalfa was not bonded in the center of the specimen and became two pieces when it was removed from press.
Statistics.
Analysis of variance in each of the above examples was performed using the ANOVA protocol of the SAS system (SAS Institute, Cary, N.C., 1998). Mean separations were performed using Duncan's multiple range test, at a significance level of P<0.05.
TABLE 1
Growth conditions for generating fermentation residues
Cellulose
Residue
source and
Incubation
dry
Residue a
Bacterium
amount (g)
time (h)
weight (g)
Ra7 WFR1
R. albus 7
CF1 (160)
88
NT b
Ra7 LFR 2
R. albus 7
SC50 (120)
108
25.6
RfB34b LFR
R. flavefaciens
SC50 (120)
100
79.5
FD-1
RfFD-1 LFR
R. flavefaciens
SC50 (120)
96
80.2
B34b
a FR, fermentation residue that was tested either wet (WFR) or lyophilized and rehydrated (LFR).
b NT, not tested
TABLE 2
Composition of fermentation residues
Mol % neutral sugar composition of
Protein
Alkali-soluble CHO
TFA hydrolyzate of NDF b
(% dry wt)
(% dry wt) a
Glc
Gal
Man
Xyl
Ara
Ra7 FR1
4.88 ± 0.14
23.1 ± 2.1
NT c
Ra7 LFR 2
3.77 ± 0.13
20.3 ± 0.1
69.2 ± 0.6
2.3 ± 0.3
8.3 ± 0.3
19.4 ± 0.5
0.5 ± 0.2
RfB34b LFR
0.42 ± 0.01
13.6 ± 1.1
72.2 ± 1.9
1.9 ± 0.1
7.4 ± 0.5
18.0 ± 1.3
0.2 ± 0.1
RfFD-1 LFR
1.41 ± 0.01
22.4 ± 6.9
73.1 ± 0.4
2.6 ± 0.5
7.3 ± 0.3
16.8 ± 0.5
0.3 ± 0.1
Ctc 27405 LFR
NT c
NT c
61.0 ± 9.4
4.8 ± 3.4
13.1 ± 3.0
21.3 ± 2.9
<0.1
a Percentage of residue dry matter converted to phenol/sulfuric acid-reactive carbohydrate after treatment with 1 N NaOH, 70° C., 1 h. Results are mean values of duplicate samples ± S.E.M.
b Neutral detergent fiber of residue isolated by the method of Goering and Van Soest (1970). See text for details of TFA hydrolysis. Results are mean values of duplicates samples ± S.E.M. Rhamnose and fucose were <0.2% for all samples.
c NT = Not tested
TABLE 3
Adhesive formulations and pressing times used to
produce aspen plywood sheets
Press
Number
PF
GLU-X
FR b
H 2 O
time
of
Adhesive a
(g) c
(g) c
(g) c
(g)
(min)
panels
PF
18.9
3.9
0
0
5
3
Ra7 WFR1
0
0
9.24
0
10
2
Ra7 LFR 1
0
0
11
22
10
2
PF + Ra7 LFR 2 (8)
11.76
0
2
0
10
2
PF + Ra7 LFR 2 (40)
2.94
0
2
4
5
1
PF + Ra7 LFR 2 (73)
1.47
0
4
8
8
1
RfB34b LFR
0
0
11
22
10
2
RfFD-1 LFR
0
0
11
22
10
2
PF + RfB34b LFR (40)
2.94
0
2
4
10
2
PF + RfB34b LFR (73)
1.47
0
4
8
10
2
PF + RfFD-1 LFR (40)
2.94
0
2
4
10
2
PF + RfFD-1 LFR (73)
1.47
0
4
8
10
2
a LFR = lyophilized fermentation residue, WFR = wet fermentation residue. Ra7, Ruminococcus albus 7; RfB34b, R. flavefaciens B34b; RfFD-1, R. flavefaciens FD-1. Values in parentheses correspond to percentage by weight of fermentation residue.
b Fermentation residue (WFR or LFR)
c Dry weight basis
TABLE 4
Adhesive formulations and pressing times
used to produce aspen 3-ply panels
PF
Glu-x + walnut shell flour (1:1)
AR b
H 2 O
Adhesive a
(g)
(g)
(g)
(g)
5778ext
69.0
12.7
0
18.3
unalf30
69.0
0
12.7
18.3
raalf30
69.0
0
12.7
18.3
ctalf30
69.0
0
12.7
18.3
raalf45
37.0
0
12.7
50.3
ctalf45
37.0
0
12.7
50.3
a The phenol formaldehyde resin, PF (GP5778) contains 42% solids. 30 = 30% of total solids, 45 = 45% of total solids.
b Alfalfa residue (alf), unfermented (un) or fermented (ra or ct). | A bioadhesive composition for bonding together adjacent surfaces of wood comprises a microbially-produced fermentation residue containing adherent microbial cells and glycocalyx. This residue finds particular application as a replacement for a significant amount of phenol-formaldehyde (PF) or other conventional adhesive component commonly used in the production of plywood and other wood products. | 2 |
CROSS-REFERENCE TO RELATED INVENTIONS
[0001] This application is a Continuation-in-Part of pending application Ser. No. 14/341,696 filed Jul. 25, 2014 and claims the benefit of PCT Application Number PCT/US15/50991, filed Sep. 18, 2015, the disclosures of which are hereby incorporated herein by reference.
TECHNICAL FIELD AND INDUSTRIAL APPLICABILITY OF THE INVENTION
[0002] This invention relates to the manufacture of a heater for warming shaving and cosmetic products. The heater includes an induction heating system mounted within a housing for heating a conductive target member disposed within a top surface region of a shaving or cosmetic product stored within a product container removably received in an induction receptacle. An induction-heating coil of the induction heating system is mounted adjacent the induction receptacle. When the heating system is activated, an electromagnetic field is generated within the product container for heating only the target member and thereby heating only a “heat affected product zone”. The “heat affected product zone” is the upper surface region of the product immediately above and below the target member wherein the product becomes heated and or melted and staged for the user.
BACKGROUND OF THE INVENTION
[0003] Basic principles of induction heating date back to Michael Faraday's work in 1831. Induction heating is the process of heating an electrically conductive object by electromagnetic induction, where eddy currents are generated within the target workpiece. This technology is widely used in industrial welding, brazing, bending, and sealing processes. Also, induction heating has grown very popular in culinary applications, providing a more efficient and accelerated heating of liquids and/or foods on stovetops or in ovens. Advantages of using an induction heating system are an increase in efficiency by using less energy and also generating heat to a specific target member.
[0004] Applying heated shaving cream or cleansing gel to the skin opens pores translating in a more comfortable shave or a more effective skin cleansing. Currently the process of heating shaving cream to the desired temperature is difficult. It requires meticulous attention and practice. Overheating can ruin the product and under-heating does not generate the desired effect. The technology available to heat shaving cream often requires shaving cream to be in an aerosol dispensed can. An aerosol based shaving cream is often times of poor quality. These shaving cans are often destroyed by repeated process of heating, and also unevenly heat the product. Resistance heating of the can is also extremely inefficient and causes the shaving can to remain hot for long periods after use. In the previously mentioned heating methods, the portion of product or material not used in the container is also cyclically heated. This cyclic heating degrades the composition of the product or material.
[0005] One attempt of using an induction heating system is disclosed by Brown, et al. in US 20080257880 A1. Brown, et al. disclose an induction heating dispenser having a refill unit 8 heated by primary and secondary induction coils 2 and 13 . As disclosed in paragraph [0020], the dispenser can be used for many different applications such as air fresheners, depilatory waxes, insecticides, stain removal products, cleaning materials, creams and oils for applications to the skin or hair, shaving products, shoe polish, furniture polish, etc. The refill unit 8 comprises a multiplicity of replaceable containers 9 for holding the respective products. The containers are sealed under a porous membrane 11 . As disclosed in paragraph [0011], the porous membrane is usually removed for meltable solid substances. For volatile liquid substances, the porous membrane is not removed. As disclosed in paragraph [0023], the porous membrane 11 has a porosity that allows vapor to pass through but not liquid to prevent spillage. Also, in paragraph [0020], for heated products that are applied to a surface, the container may have an associated applicator such as a brush, pad or sponge.
[0006] Another heated dispenser system is disclosed by Bylsma, et al. in US 20110200381 A1. Bylsma, et al. disclose a dispenser wherein the heating unit could be either in the base unit 10 as illustrated in FIG. 4 , or in the applicator 42 as illustrated in FIG. 5 . As disclosed in paragraph [0026], the heating unit may be an inductive power coupling. As disclosed in paragraphs [0030-0036], the applicator may be of many different forms depending on the product to be dispensed.
[0007] Although the prior art systems have proven to be quite useful for their purposes, none have been designed to be energy efficient or to heat and/or melt only the amount of composition necessary for the immediate application as accomplished by the present invention.
[0008] Therefore, it is an object of this invention to provide an improvement which overcomes the aforementioned inadequacies of the prior art devices and provides an improvement which is a significant contribution to the advancement of the induction heating art.
[0009] The foregoing has outlined some of the pertinent objects of the invention. These objects should be construed to be merely illustrative of some of the more prominent features and applications of the intended invention. Many other beneficial results can be attained by applying the disclosed invention in a different manner or modifying the invention within the scope of the disclosure. Accordingly, other objects and a fuller understanding of the invention may be had by referring to the summary of the invention and the detailed description of the preferred embodiment in addition to the scope of the invention defined by the claims taken in conjunction with the accompanying drawings.
SUMMARY OF THE INVENTION
[0010] The present invention relates generally to a heater for warming products such as soaps, creams, lotions, gel compositions or other solutions (hereinafter “product”) for shaving purposes or cosmetic purposes such as skin cleansing. The products are stored in a container wherein only the upper portion of the products is heated and/or melted by an induction-heating device. An electrically conductive metallic member (hereinafter “target member”) having through-passages is positioned generally on the top surface of the product within the product container. As the target member becomes heated by the induction system, the heated and/or melted product flows through the through-passages. The present invention instantaneously heats only a portion or volume of product necessary for immediate application by the user.
[0011] The present invention is an induction-heating device having a housing with a top outer surface defining an induction receptacle. Mounted within said housing is an electromagnetic heating circuit and an induction coil. The induction coil is disposed in parallel relation to the induction receptacle as described hereinafter. A user interface is also mounted in the top surface of the housing for controlling the warming and/or melting or liquefying the product in the “heat affected product zone”. The device includes an induction receptacle that accepts a product container filled with a product. The electromagnetic heating circuit and induction coil generate an electromagnetic field within the product container that induces eddy currents into the target member thereby heating the target member. The present invention may be further characterized in that the induction coil may have various configurations as described in further detail hereinafter for varying the electromagnetic field. Inside the product container, the target member is disposed across the top surface of the product. The target member comprises through-passages for allowing heated and/or melted product to flow therethrough. The heat generated in the target member is then conducted to the “heat affected product zone” of the product to heat and/or melt or liquefy only the product in the “heat affected product zone”. The target member then acts as an interface between the user (or user's brush, pad, cloth, finger, and the like) and the product. The target member may be comprised of various geometric configurations that allow the user to stir or agitate different products to the desired temperature and/or consistency. In applications requiring the product to be heated (such as cosmetics, lotions, creams, balms, waxes, etc.), the target member would be predominantly flat. In applications requiring the product to be heated and lathered, the target member would be comprised of non-flat geometry including raised portions or indentions depending on orientation of the target member within the product receptacle. Alternative to a relatively flat profile, the target member may be dish-shaped, cup-shaped or corrugated-shaped. The target member may comprise an electrically conductive disc made of a metal screen, a metal plate perforated with holes, slots or a combination of holes and slots, all of which provide through-passages to allow product to pass therethrough. Although the preferred shape of the target member is disc-shaped, other geometric shapes may also be employed such as square-shaped or rectangular-shaped depending on the shape of the product container as discussed in more detail hereinafter. As the product in the heat affected product zone is only heated and/or melted, an applicator such as a shaving brush or skin pad can be used to collect the heated and/or melted product from the upper surface of the target member which can be applied to the face or any other desired location of the body. The present invention is a more effective means of heating the product; especially for an amount necessary for the immediate application since only the product in the heat affected product zone is heated and/or melted. As different products may be stored in different containers, the containers of product are easily accessible and interchangeable from the induction receptacle. A unique RFID tag is incorporated into each product cup to allow the product and associated target member to be uniquely identified by the induction system to provide the necessary heating according to the advantages of the present invention. The present invention has no open flame, operates silently, and stays cool after the cup is removed. Furthermore, the product will return to its original form (e.g., solid, cream or gel) more quickly than if the entire product was melted, minimizing degradation of the product.
[0012] The foregoing has outlined rather broadly the more pertinent and important features of the present invention in order that the detailed description of the invention that follows may be better understood so that the present contribution to the art can be more fully appreciated. Additional features of the invention will be described hereinafter which form the subject of the claims of the invention. It should be appreciated by those skilled in the art that the conception and the specific embodiment disclosed may be readily utilized as a basis for modifying or designing other structures for carrying out the same purposes of the present invention. It should also be realized by those skilled in the art that such equivalent constructions do not depart from the spirit and scope of the invention as set forth in the appended claims.
BRIEF DESCRIPTION OF THE DRAWINGS
[0013] For a fuller understanding of the nature and objects of the invention, reference should be had to the following detailed description taken in connection with the accompanying drawings in which:
[0014] FIG. 1 is an exploded view of a first embodiment of the present invention trapezoidal-shaped housing.
[0015] FIG. 2 is a cross-sectional view along the lines II-II shown in FIG. 1
[0016] FIG. 3 is a cross-sectional view along the lines II-II shown in FIG. 1 inclusive of the induction heating system.
[0017] FIG. 4 illustrates the stages that a product within a product cup undergoes during a single heating cycle.
[0018] FIG. 5A is a perspective view of a second embodiment of the present invention illustrating an assembled induction receptacle, product cup and target member comprising a screen bound by a floatation ring.
[0019] FIG. 5B is an exploded view of the second embodiment of the present invention illustrated in FIG. 5A .
[0020] FIG. 6 is a circuit block diagram of the electronic system of the present invention.
[0021] FIG. 7 is a perspective view of the actual arrangement of components within the present invention.
[0022] FIG. 8 illustrates an exploded view of a third embodiment of the present invention similar to the first embodiment but with a rectangular-shaped housing and modified cylindrical induction coil configuration.
[0023] FIG. 9 illustrates an exploded view of a fourth embodiment of the present invention having a modified induction receptacle and product cup and a modified coil configuration.
[0024] FIG. 10A shows perspective view of a fifth embodiment of the present invention similar to the second embodiment illustrated in FIG. 5A wherein the floatation ring is eliminated.
[0025] FIG. 10B is an exploded view of the fifth embodiment of the present invention illustrated in FIG. 10A .
[0026] FIG. 11A shows a perspective view of a sixth embodiment of an induction receptacle, product cup and target member usable with the fourth embodiment illustrated in FIG. 9 .
[0027] FIG. 11B is an exploded view of sixth embodiment of FIG. 11A .
[0028] FIGS. 12 through 20 show various embodiments of target members.
[0029] FIG. 21 shows a high level flowchart demonstrating the process by which the input power is transferred to the target member.
[0030] FIG. 22 shows a flowchart of the decision making process of the present invention.
[0031] Similar reference characters refer to similar parts throughout the several views of the drawings.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0032] As illustrated in FIG. 1 , an exploded view of a first embodiment of the present invention basically includes an induction heating unit main housing ( 1 ) connected to a power supply ( 2 ). In describing the structure of the present invention, elements common to each embodiment will be given the same numerals. The main housing ( 1 ) has a top outer surface ( 1 A) with an opening ( 1 B). An induction receptacle ( 4 ) is mounted in the main housing ( 1 ) through opening ( 1 B). An induction-heating coil ( 3 ) is mounted adjacent the induction receptacle ( 4 ). A product container ( 6 ) is removably inserted within the induction receptacle ( 4 ). In this first embodiment, the product container ( 6 ) includes flange ( 6 D) for receiving a closure (not shown) such as a conventional foil adhered to the flange.
[0033] Referring to FIGS. 2 and 3 , illustrated are cross-sections along lines II-II indicated in FIG. 1 . The induction receptacle ( 4 ) has an open top extending through the top surface ( 1 A). The induction-heating coil ( 3 ) surrounds the induction receptacle ( 4 ) and is controlled by microprocessor ( 19 ). The preferred diameter of the cup is between 2 and 4 inches (5.08 and 10.16 cm). Illustrated as (H) in FIG. 3 , the height of the cup is between 0.5 to 2 times the diameter of the cup. Although the induction receptacle and product container are illustrated in the form of cylindrically shaped cups, the shape of the induction receptacle and product container is not intended to be so limited and other geometric configurations may be employed. Also, the product cup ( 6 ) shown in FIGS. 2 and 3 includes an upper threaded extension ( 6 E) for receiving a threaded closure (not shown).
[0034] Referring to FIG. 3 , an RFID tag ( 14 ) is mounted on or in the bottom surface of the product container ( 6 ) for transmitting data to the RFID reader ( 27 ) which translates information to the microprocessor ( 19 ) such as cycle time, resonant frequency of target member, product type, and other parameters needed to heat the product according to requirements. To ensure the key objectives of the present invention, i.e., immediate heating of the product for an application and to minimize the degradation of the product, the present invention requires the successful transmission of the information from the RFID tag ( 14 ) to the RFID reader ( 27 ). A conductive target member ( 7 ) having through-passages ( 7 A) is removably inserted within product container ( 6 ) and initially rests on the upper surface ( 6 B) of an unheated product ( 6 A) contained within the container. By using the terminology “conductive target member” herein is meant that it is the only structural element of the present invention within the product container ( 6 ) that is heated by the induction-heating coil ( 3 ). The heat from the “conductive target member” is then transferred to the “heat affected product zone” as described hereinbefore. As explained and emphasized in further detail hereinafter, the cycle time is adjusted to heat and/or melt the product only in the “heat affected product zone” thereby allowing product to flow through the through-passages. Once the cycle time is completed and the product cools and returns to its initial state, the target member remains embedded within the upper surface region of the product. The materials used to manufacture the main housing ( 1 ), induction receptacle ( 4 ) and product container ( 6 ) are non-metallic and non-electrically conductive. Such materials are well known and may include any type of well known polymeric composition. With the selection of materials used to manufacture the present invention and the operation of the present invention as described hereinafter, the heated target member ( 7 ) heats and/or melts the product only in the “heat affected product zone”. The product itself is not heated directly by the induction heater coil ( 3 ). Also shown is operator interface or user interface window ( 5 ) in a side surface of housing ( 1 ) that allows the user to interact with the device through visual and touch based actions. The target member ( 7 ) in the embodiment illustrated in FIG. 1 is an electrically conductive metallic screen. The interstices between the metallic strands of the screen constitute through-passages. It is noted that the target member ( 7 ) comprises a geometry to nest within the product container ( 6 ), which comprises a geometry to nest within the induction receptacle ( 4 ). In other words, the peripheral dimensions of the target member ( 7 ) and in all embodiments of the present invention described herein are slightly less than the interior dimensions of the product container whereby the target member is free to fall within the product container as the product diminishes with each use. Also, the outer peripheral dimensions of the product container are slightly less than the interior dimensions of the induction receptacle.
[0035] Referring to FIG. 4 , the stages that the product undergoes during a heating cycle are illustrated. The region or volume within the product cup that is only heated during each stage of a heating cycle is the “heat affected product zone” indicated as (X). It is emphasized that this is a key focus of the present invention because only the product in the “heat affected product zone” is heated and not the entire product which would diminish effectiveness of the product over time. In the product cup marked “Before”, a cross section containing unheated product ( 6 A) is shown with a target member resting on an upper surface ( 6 B) of the product ( 6 A). In the product cup marked “During”, the product is heated in the heat affected product zone (X), which is the region immediately above, below, and including the target member in which the product becomes heated and staged for the user. During this stage, as the heating cycle begins, an electromagnetic field passes electromagnetic energy within the target member (described in more detail hereinafter) thereby heating the target member. Heat then transfers to the product that is in contact with the target member. The heated product melts or liquefies and then flows through the target member through-passages ( 7 A) to the upper surface of the target member ( 7 ). The heated product located on the upper surface of the target member is then ready for stirring and/or gathering such with a brush, scraper or fingers by the user. During the heat cycle the target member may descend though the product due to gravity or may rely on the downward force by the user. In the product cup marked “After”, the induction heating cycle has ended and the product and target member begin to cool. As a result the viscosity of the product increases and in some instances the product returns from a liquid state to a solid or gelatinous state. Also, after the product has cooled, a residual layer of product ( 6 C) will remain on the upper surface of the target member ( 7 ).
[0036] Referring to FIGS. 5A and 5B , the embodiment illustrated includes a target member ( 9 ) illustrated as an electrically conductive metallic screen and floatation device ( 10 ) removably inserted within product container ( 12 ), which is removably inserted within induction receptacle ( 11 ). The product container ( 12 ) does not include an upper outwardly extending flange or threaded extension as does the product container ( 6 ) in FIGS. 1-4 . In this embodiment, a plug-type of closure (not shown) is used to close the product container for storage. The induction receptacle ( 11 ) and product container ( 6 ) are modified with a non-circular geometry. In particular, each component has at least one flat surface for aligning the components in assembled position and preventing rotation while collecting the product onto the applicator. Although this embodiment is shown to have flat surfaces, any other configuration could be employed to align and prevent rotation of the components during use.
[0037] Referring to FIG. 6 , a circuit block diagram of the present invention is illustrated. A standard wall outlet AC line input ( 13 ) is connected to a standard electromagnetic transformer ( 15 ) and AC to DC rectifier ( 16 ) enclosed within the housing ( 2 ) to power the components. The system further includes a standard DC circuit breaker ( 33 ) and regulator chip ( 17 ) that lowers the voltage to power the sensitive digital components. An operator interface ( 18 ) is accessed by window ( 5 ) shown in FIGS. 1-3, 8 and 9 enabling a user to interact with the device. A microprocessor unit ( 19 ) controls level of electromagnetic energy in the resonant tank ( 26 ) described in further detail hereinafter to an induction coil ( 3 ). The induction coil ( 3 ) is disposed adjacent the induction receptacle ( 4 ) shown in FIG. 3 . The conductive target member ( 7 ) is disposed within the product container ( 6 ) that is removably received within the induction receptacle ( 4 ). The microprocessor ( 19 ) varies the level of heat energy induced into the conductive target member ( 7 ) by adjusting the oscillation frequency in the HF converter ( 25 ) by means of pulse width modulation (PWM). The microprocessor ( 19 ) also controls the operator interface ( 18 ), temperature sensor ( 20 ), current sensor ( 21 ), antenna ( 22 ), signal processor ( 24 ), RFID reader ( 27 ) and electro-acoustic transducer ( 23 ). The temperature sensor ( 20 ) is capable of reading the internal board component temperatures of the microprocessor as well as the temperatures of the induction coil windings. The current sensor ( 21 ) is configured to measure the current draw through the switching circuit within the microprocessor. The antenna ( 22 ) can be any conventional type such as a dipole, helical, periodic, loop, etc., and is configured to receive information from remote modules or transmit data to an external remote control device, for example, via Bluetooth technology. The electro-acoustic transducer ( 23 ) can be any conventional type, such as a speaker, capable of producing warnings such as over-heating temperatures or other helpful aids to the user throughout the heat cycle. It may also provide instructions during the product application. The transducer may also be configured in such a manner that it records electrical-mechanical pulses and is read by a signal processor ( 24 ). The signal processor ( 24 ) is a standard signal-processing unit used to decode information received from antenna ( 22 ) and transmits information via the electro-acoustic transducer ( 23 ). The HF inverter ( 25 ) converts DC power to high frequency AC by means of receiving pulse width modulated signals from the microprocessor ( 19 ) and receiving high levels of DC power from rectifier ( 16 ). The high frequency AC generated by inverter ( 25 ) is then passed into a series, parallel, quasi-series, or quasi-parallel resistor, capacitor, and inductor network called a Resonant Tank ( 26 ). Tank ( 26 ) has a resonant frequency determined by the resistor, inductor, and capacitor (RLC) configuration therein. As current passes through the resonant tank ( 26 ), it travels through the induction coil which is a large wound conductive copper induction coil shown as element ( 3 ) in FIGS. 1 and 3 , as element ( 3 A) in FIG. 8 , and as element ( 3 B) in FIG. 9 . The RFID reader ( 27 ) is mounted within the main housing ( 1 ) in close proximity to the bottom of the induction receptacle ( 4 , 4 A and 11 ) in order to communicate with the RFID tag ( 14 ) on or in the bottom of the product container ( 6 , 6 A or 12 ). The Resonant Tank ( 26 ) frequency is optimized through means of electrical reprogramming and tuning carried out by the microprocessor ( 19 ) and high frequency inverter ( 25 ). The optimization of the resonant tank is achieved by user input and/or information generated by the RFID tag ( 14 ) located on the product cup. This system allows the device to deliver precise amounts of current into the induction coil ( 3 ) to heat the “conductive target member” ( 7 ), which also limits the system from overheating the various components of the system. During the heat cycle and during non-heating idle time the microprocessor ( 19 ) monitors the current sensor ( 21 ) and temperature sensors ( 20 ) to ensure safe operation of the device. The coil is not visible to the outside of housing ( 1 ) and surrounds induction receptacle ( 4 ) and nested product container ( 6 ) with target member ( 7 ) resting on the top surface of the product within product container ( 6 ). Thus, the target member ( 7 ) is closely positioned with respect to the coil ( 3 ), which creates an electromagnetic field that passes electromagnetic energy into the conductive target member ( 7 ). By this process, the target member only is heated by the electromagnetic energy, which is then transferred to the “heat affected product zone” (X) within the product container. It is again emphasized here that the target member only and not the induction receptacle and product container is heated by the electromagnetic energy. The power supply components as described supra is not intended to be limited as will be described hereinafter.
[0038] Referring to FIG. 7 , a perspective view of how the components illustrated in FIG. 6 are arranged in main housing ( 1 ). The RF module ( 31 ), which comprises the antenna ( 22 ) and signal processor ( 24 ) seen in FIG. 6 , microprocessing unit ( 19 ), DC regulator ( 17 ), HF converter ( 25 ), resonant tank ( 26 ), speaker ( 23 ), current sensor ( 21 ), temperature sensor ( 20 ) are mounted on a main board ( 32 ). Power is fed in from a standard electrical wall outlet mains AC at ( 13 ). Power fed in is received by power supply ( 2 ) which includes transformer ( 15 ) and AC-DC rectifier ( 16 ) where it is converted into DC power and sent to the remaining components via the DC regulator ( 17 ) located on the main board ( 32 ). A circuit breaker ( 33 ) is utilized as a safety fault in the event of a large current consumption by the device. The operator interface ( 18 ) connects into the main board by means of a multi-conductor cable harness ( 35 ). The RF module ( 31 ) transmits and receives information through antenna ( 22 ). Data received and sent passes through a signal processing unit ( 24 ) to microprocessor ( 19 ). The main board ( 32 ) is controlled by microprocessing unit ( 19 ). Low voltage DC power is converted from high voltage DC by means of a DC regulator IC chip ( 17 ) located on the main board ( 32 ). The RFID reader ( 27 ) is mounted within housing ( 1 ) in close proximity to induction receptacle ( 4 ) for communicating with RFID tag ( 14 ).
[0039] Referring to FIG. 8 , a third embodiment of the present invention is illustrated which is similar to the embodiment illustrated in FIG. 1 with the exception of induction coil ( 3 A) and shape of the main housing ( 1 ). The induction coil illustrated in FIG. 2 is configured to have even windings from top to bottom. However, the configuration of the induction coil may be arranged or formed to meet different requirement per product. The embodiment illustrated in FIG. 1 shows an induction coil ( 3 ) formed into an evenly pitched helix for relatively even heating of the target member ( 7 or 9 ) as it descends from the top of the product container ( 6 ) to the bottom. The embodiment illustrated in FIG. 8 shows the induction coil ( 3 A) wound with variable pitch allowing for variable heating as the target member descends in the product cup from the top to the bottom. This may advantageously be used to increase, decrease, or make even the heating as the target member descends though the coil. This embodiment may further provide the user with product heated to a higher level when the product container is full. As the product diminishes, the level of heat is reduced to avoid damaging the product from overheating. Thus, the user is provided with uniformly heated product throughout the entirety of product within the product container. It is well known that despite even coil pitch the flux lines of energy may be denser in certain areas, specifically towards the center height of the helix coil. This may be offset by varying the pitch of the helix only in this area. Alternatively, heat generated within the target member may be controlled by indirectly measuring the inductance of the system and varying the frequency thereof. Most preferably, the present invention utilizes the unique RFID tag associated with each product cup, associated with each target member, to properly regulate the parameters that relate to the heating cycle. In this embodiment, the main housing has a rectangular shaped housing having interface ( 5 ) located on a top surface thereof.
[0040] Referring to FIG. 9 , a fourth embodiment of the present invention is illustrated which is similar to the embodiment illustrated in FIG. 8 with the exception of the induction coil ( 3 B), which is formed as a pancake coil. Also, the induction receptacle ( 4 A) and product container ( 6 A) have an overall depth much less than the induction receptacles and product containers of the previous described embodiments. All other components are the same as those of the embodiments illustrated in FIG. 2 or 8 . The effective height of the electromagnetic field generated by the pancake coil ( 3 A) is much less than that of the cylindrical coils of the previous embodiments thus taking into account the lesser overall depth of the product receptacle ( 4 A) and product container ( 6 A). In other words, the effective distance of the electromagnetic field generated by the pancake coil ( 3 A) is sufficient to heat the target member disposed at an upper region of the product within the product container of lesser height.
[0041] Referring to FIGS. 10A and 10B , the embodiment illustrated is similar to the embodiment illustrated in FIGS. 5A and 5B . The target member ( 9 ) is removably inserted within product container ( 12 ), which is removably inserted within induction receptacle ( 11 ). The components of this embodiment are similar to those shown in FIGS. 5A and 5B with the exception that the target member does not include a floatation ring. The target member ( 9 ) comprises geometry to nest within the product container ( 12 ), which comprises geometry to nest within the induction receptacle ( 11 ). In this variant, the assembly is comprised of an asymmetrical geometry about a medial plane to prevent the rotation of the target member when stirred or agitated. The product container is between 2 and 5 inches (5.08 and 12.7 cm) deep requiring use of coils along the sides of the induction receptacle. In particular, the cross-section of each component has at least one flat side surface for aligning the components in assembled position and preventing rotation while collecting the product onto the applicator. Although this embodiment is shown to have flat side surfaces, the cross-sectional configuration of each component could be of any geometric shape to align and prevent rotation of the components during use.
[0042] Referring to FIGS. 11A and 11B , the alternative embodiment illustrated includes a target member ( 9 ) illustrated as an electrically conductive metallic screen removably inserted within product container ( 12 A), which is removably inserted within induction receptacle ( 11 A). This embodiment is to be used with the pancake coil in the embodiment illustrated in FIG. 9 . The components of this embodiment are similar to those shown in FIGS. 5A, 5B, 10A and 10B with the exception that the target member does not include floatation ring and the overall depth of the induction receptacle and product container is less. In this embodiment, the product container ( 12 A) is between 0.500 and 2 inches (1.27 and 5.08 cm) deep requiring use of the pancake coil along the bottom of the induction receptacle. This provides opportunity for the user to introduce product as needed into the product container or to have a greatly reduced starting sample size. As in the previous embodiments, the cross-section of each component has at least one flat side surface for aligning the components in assembled position and preventing rotation of the target member while collecting the product onto the applicator, and the cross-sectional configuration of each component could be of any geometric shape to align and prevent rotation of the components during use.
[0043] Referring to FIGS. 12-19 , alternative to the electrically conductive screen type target member illustrated in the embodiments described above, other embodiments of target members are shown that can be employed in each of the embodiments described supra. Applicants have discovered that by varying the construction of the target member, the heating pattern on the target member can be modified. Each target member illustrated in FIGS. 12-19 comprises a solid metallic disc member having an outer peripheral surface ( 51 ), an upper surface ( 52 ) and a lower surface ( 53 ). The peripheral surface ( 51 ) is where heat originates due to the concentration of flux lines from a cylindrical coil such as seen in FIGS. 2 and 8 . The top surface ( 52 ) provides the surface area that that the user will interface with. The bottom surface ( 53 ) is the area or region that first provides heat to the product.
[0044] As illustrated in FIGS. 12 and 12A , target member ( 35 ) comprises a solid metallic disc member having an outer peripheral surface ( 51 ), an upper surface ( 52 ) and a lower surface ( 53 ). A plurality of evenly distributed holes or through-passages ( 37 ) extend therethrough and are located in spaced relation between the outer peripheral surface ( 51 ). In the preferred embodiment, six holes or through-passages ( 37 ) are circular and have a diameter ranging between 0.030 to 1.000 inches (0.076 to 2.54 cm), most preferably between 0.030 and 0.400 inches (0.076 and 1.016 cm). In this embodiment, heat is propagated from the outer peripheral surface towards the center axis of the target member. As the target member is energized by electromagnetic field from the induction coil, the heat generated in the target member ( 35 ) is focused in the peripheral region indicated by the cross-hatching ( 36 ).
[0045] Referring to FIG. 13 , target member ( 39 ) comprises a solid metallic disc with peripheral, upper and lower surfaces (not numbered). In this embodiment, the target member includes through-passages comprised of four radially extending slots ( 40 ) dividing the disc into four separate quadrants ( 42 ) having slots ( 41 ) each connected by a central section ( 43 ). Each quadrant includes a centrally disposed slot ( 41 ) having sharp and/or rounded corners. This embodiment provides an increased rate of heat transfer within the conductive material from the heat region ( 44 ) to the center of the target member due to the absence of material and also by the outer slots ( 40 ) that direct the eddy current along the peripheral surface towards the center. The slots ( 40 ) and ( 41 ) extend entirely through the disc from the upper surface to the lower surface. In this embodiment, as the target member is energized by electromagnetic flux from the induction coil, the heat generated in the target member ( 39 ) is focused in the areas indicated by the cross-hatching ( 44 ).
[0046] Referring to FIG. 14 , target member ( 45 ) comprises a solid metallic disc with peripheral, upper and lower surfaces (not numbered). In this embodiment, the target member includes through-passages comprised of radially extending square-shaped slots ( 46 ) spaced equidistant from each other. Each slot extends inwardly from the peripheral surface to a point in the peripheral region ( 47 ) of the disc. These square slots are comprised of only straight walls and 90 -degree angles to propagate the heat zone ( 48 ) inward from the periphery of the target member. This assists in more even heat distribution through the target member.
[0047] Referring to FIG. 15 , target member ( 49 ) comprises a solid metallic disc with peripheral, upper and lower surfaces (not numbered). This embodiment includes through-passages comprised of radially extending slot ( 50 ) and crescent-shaped slot ( 53 ). Slot ( 50 extends from the peripheral surface to one corner of a central diamond-shaped cutout ( 51 ). Except for the corner where the slot ( 50 ) enters the diamond-shaped cutout, the remaining corners are formed with pronounced peaks ( 52 ). Crescent-shaped slot ( 53 ) surrounds the slot ( 50 ) and diamond-shaped cutout ( 51 ). The slots ( 50 ) and ( 53 ) and diamond-shaped cutout ( 51 ) extend entirely through the disc from the upper surface to the lower surface. The remainder of the disc is solid. In this embodiment, as the target member is energized by electromagnetic flux from the induction coil, the heat generated in the target member ( 49 ) is focused in the regions indicated by the cross-hatching ( 54 ).
[0048] Referring to FIGS. 16 and 17 , target member ( 55 ) comprises a solid metallic disc with peripheral, upper and lower surfaces (not numbered). In this embodiment, the target member ( 55 ) is similar to the target member illustrated in FIG. 12 and therefore, would have the very similar heat distribution. However, this embodiment differs from that of FIG. 12 in that each hole ( 57 ) is surrounded by an upstanding conical member ( 56 ). The upstanding conical members facilitate agitation and lathering of the melted product as it flows through holes or through-passages ( 57 ) and collected by the user such as by a shaving brush. Each conical member extends between 0.010 and 0.250 inches (0.0254 and 0.635 cm) from the upper surface of the target member. Each hole ( 57 ) may be between 0.020 and 0.750 inches (0.05 and 1.9 cm) in diameter. In this embodiment, although no cross-hatching is shown, as the target member is energized by electromagnetic flux from the induction coil, the heat generated in the target member ( 55 ) is focused in the same region indicated by the cross-hatching ( 36 ) in FIG. 12 .
[0049] Referring to FIGS. 18 and 19 , target member ( 58 ) comprises a solid metallic disc with peripheral, upper and lower surfaces (not numbered). In this embodiment, the target member ( 58 ) includes a through-passage comprised of a single central large hole ( 60 ) extending therethrough from the upper surface to the lower surface. A plurality upstanding ribs ( 59 ) are evenly disposed on the upper surface. The upstanding ribs provide agitation to the melted product as it flows through hole ( 60 ) to create lather when the melted product is collected by the user such as by a shaving brush. In this embodiment, although no cross-hatching is shown, as the target member is energized by electromagnetic flux from the induction coil, the heat generated in the target member ( 58 ) is evenly focused about each of the upstanding ribs ( 59 ).
[0050] Referring to FIG. 20 , the target member illustrated is the conductive metallic screen ( 7 or 9 ) shown in the embodiments of FIGS. 1 and 8-11 . The screen is comprised of woven strands of electrically conductive material, preferably aluminum or stainless steel. The woven strands are between 0.010 and 0.070 inches (0.0254 and 1.778 cm) in diameter with an open area between 20 and 85 percent of the whole area. The interstices between the woven strands constitute through-passages for heated and/or melted product to flow through the target member. The heat zone ( 61 ) propagates from four outer peripheral regions towards the center. These four outer peripheral regions are located at the points on the peripheral surface where the longest strands intersect the peripheral surface. The contact points of the strands are preferably joined to facilitate even distribution of the heat zone. The varying topology of the top surface of this embodiment provides the user with an area that is highly advantageous for creating lather. In this embodiment, as the target member is energized by electromagnetic flux from the induction coil, the heat generated in the target member is focused about its peripheral region as indicated by the cross-hatched area ( 61 ).
[0051] Although only indicated in FIG. 12A , all the target members illustrated in FIGS. 12-19 have a material thickness (h) ranging between 0.005 and 0.150 inches (0.0127 and 0.0381 cm), most preferably between 0.008 and 0.020 inches (0.020 and 0.050 cm), and a width (w) ranging between 2 and 4 inches (5.08 cm and 10.16 cm). The various target member configurations illustrated in FIGS. 12-19 provide differing heating characteristics by changing or interrupting the side surface ( 51 ) profile, or target member surface that is parallel to the cylindrical coil wall, of the target member. Depending on the application and heating requirement, some target members have more total surface area to provide more contact with the product, and thus faster heating of the product. The varying top surface ( 52 ) topography of each target member in conjunction with the viscosity of the product may significantly impact the rate at which the target member descends though the product. Additionally, the varying top surface topography provides opportunity for aeration. For applications requiring agitation or aeration the top surface topography of the target member possess more variance. The size and number of openings are also advantageous in providing agitation of the product for applications requiring lather, such as shaving soaps. The present invention may simultaneously utilize one or more target members composed of any of the following types of steel alloy, carbon, tool, or stainless and may be of the ferritic, martensitic, and/or austenitic grain structure. Additionally, and preferably, the target member may be of any of the SAE designated aluminum types. Aluminum, generally non-compatible with household induction heaters/cookers, provides corrosion resistance, a very low heat capacity, and high thermal conductivity as compared to other materials that work with household induction cooking/warming systems. The low heat capacity of the aluminum allows the target member to raise temperature quickly and also to cool quickly once the cycle has ended. This in turn allows the product to return to its original state more quickly than would one of the steel grades that retains more heat. A target member comprised of a material with a high heat capacity would descend downward towards the bottom of the product cup even after necessitating use due to the excess heat held within the conductive material. The high thermal conductivity of the aluminum target member is advantageous in transferring the heat generated by the eddy current to the product as quickly as possible. As a result of the high thermal conductivity and low heat capacity, the energy from the electromagnet field is instantaneously transferred to the product, in the form of heat, with minimal dwell time in the target member.
[0052] The block diagram illustrated in FIG. 21 shows the process for transferring power from its origin to heat energy within the target member. As illustrated in FIG. 6 , the Power Input Stage is in the form of alternating current as commonly sourced by the wall outlet in residential and/or commercial buildings. This alternating current passes into a rectifier stage whereby it is converted to direct current. This stage is not intended to be limiting but rather showing one suitable option. For example, the transformer and rectifier may be incorporated into the microprocessor unit. In other embodiments the AC line may be eliminated and replaced with a battery. The direct current is then converted back to a high frequency alternating current by any common oscillator circuit whether digital or analog. The high frequency alternating current then creates an electromagnetic field that generates eddy current within the target member and thus creating heat.
[0053] The diagram in FIG. 22 shows a decision making process related to the RFID system. A unique RFID tag ( 14 ) is attached to each product cup and has been pre-programmed with information used by the present invention for optimizing the induction heating cycle for the given product. After detection, the RFID reader reads the information on the RFID tag found on the internal memory blocks within the RFID tag and provides that information to the microprocessor. This information includes product type, heat cycle duration, heat level required, and induction values needed for optimization of the induction cycle, such as frequency. The system then runs the validation algorithm to determine that the RFID tag is a valid tag. This step is incorporated as a safety measure. After completing these steps, the system unlocks the system and alerts the user that the heat cycle may activated. After a given number of cycles has been run the RFID tag associated with the product cup is modified by the induction system microcontroller to provide information such as number of cycle run, duration of cycles, date, and/or other information related to product usage. Additionally, the system may render the RFID tag incapacitated for future use.
[0054] Operation of the induction heating system of the present invention is as follows. AC power supply ( 13 ) is connected to the system. Voltage received is then electromagnetically reduced by transformer ( 15 ) and converted into direct current (DC) waveform by rectifier ( 16 ). Transformer ( 15 ) and rectifier ( 16 ) may be packaged together externally in an AC to DC power supply commonly used by computers or electronic devices. Inside the device the rectified DC power is passed through DC regulator ( 17 ), a monolithic integrated circuit regulator that steps down the voltage to TTL, CMOS, ECL levels etc. The induction heater coil ( 3 ) is controlled by the microprocessor ( 19 ), which also controls the timing and frequency of the HF inverter ( 25 ), sensors ( 20 ), ( 21 ), operator interface ( 18 ), led lights ( 34 ), timers, antenna ( 22 ), speaker ( 23 ) and RFID reader ( 27 ). The microprocessor ( 19 ) may also be used to interact with many other device peripherals if needed. The microprocessor is programmed to control and vary the oscillation frequency in order to reach electromagnetic resonance between the target member and the resonant tank. The microprocessor has flash memory read-while-write capabilities and EEPROM storage used in order to store user settings, timers, and safeties. Users are able to interact with the device by visually watching or pressing the operator interface ( 18 ) or user pushbuttons ( 29 ). Display of operator interface ( 18 ) is constructed of a piezoresistive, capacitive, surface acoustic, infrared grid or similar technologies. It allows the user to press and start a heating cycle while displaying helpful information based on the temperature or duration of the cycle. Safety information can be depicted on this display or any other helpful visual aids. In addition to operator interface ( 18 ), a speaker ( 23 ) is used to provide audible feedback and alerts to the user based on the state of the heat cycle. The pushbuttons ( 29 ) are used as a secondary source of user input. Nearby LEDs ( 34 ) are used to provide a secondary visual indication of the state of the device. Pushbuttons, LEDs, and the Operator Interface may be reprogrammed by the manufacturer in order to adjust the functionality and usability throughout different device revisions. Once a heat cycle is initiated, the microprocessor ( 19 ) inputs a low voltage pulse width modulated (PWM) signal received by the high frequency (HF) inverter module ( 25 ). The inverter module switches the rectified DC power from rectifier ( 16 ) to HF alternating current power at the oscillation frequency set by the microprocessor ( 19 ). High frequency AC power is then passed into a series or parallel resonant RLC tank. The tanks capacitance, inductance, and resistance are optimized to reach the resonant frequency of the PWM signal. This resonance also matches the oscillation frequency of the target members illustrated in FIGS. 12-20 . Throughout the heat cycle, current transferred into each target member is measured by sensor ( 21 ). At this time, microprocessor ( 19 ) adjusts the oscillation frequency in order to transfer maximum power into the target members. If the current exceeds a safety limit measured by sensor ( 21 ), the device shuts off the heat cycle. Likewise, the temperature of the internal components is measured by sensor ( 20 ). This prevents the device from being left on throughout the day or operating in harsh environments. Sensor ( 20 ) also measures the induction coil ( 3 ) temperature to prevent overheating on its internal windings. During the heat cycle high frequency currents are passed through the resonant tank ( 26 ) and into the coil ( 3 , 3 A or 3 B) disposed adjacent the induction receptacle ( 4 , 4 A or 11 ) that receives the product container ( 6 , 6 A or 12 ). The high frequency currents are then transferred to the target member through means of electromagnetic induction. Eddy currents are generated inside the target member and cause a Joule heating effect as well as a heating through magnetic hysteresis. Heat generated through the target member then permeates through to the top layer of the product inside the cup. Due to the geometry of the target member, energy is transferred more directly to the “heat affected product zone” of the product inside product container ( 6 , 6 A or 12 ).
[0055] The present disclosure includes that contained in the appended claims, as well as that of the foregoing description. Although this invention has been described in its preferred form with a certain degree of particularity, it is understood that the present disclosure of the preferred form has been made only by way of example and that numerous changes in the details of construction and the combination and arrangement of parts may be resorted to without departing from the spirit and scope of the invention.
[0056] Now that the invention has been described, | An induction-heating device for heating and or melting a heat affected product zone of shaving or cosmetic products ( 6 A) stored in a product container ( 6 ) which consists of a layer of said product immediately below a top product surface and heated by an electrically conductive metallic target member ( 7 ) having through-passages overlying said top product surface and energized by an induction coil ( 3 ) into which an electromagnetic field is generated by electronic circuitry for a predetermined time period into said product container, thereby permitting said heated and or melted product to flow through said through-passages onto said top surface of said target member to be collected by a user for shaving or cosmetic purposes. | 0 |
This is a Continuation of application Ser. No. 09/925,682 filed Aug. 10, 2001 now U.S. Pat. No. 6,856,332. The entire disclosure of the prior application is hereby incorporated by reference herein in its entirety.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates generally to a video display appliance, and more particularly, to a picture adjustment method and apparatus for a video display appliance.
2. Description of the Related Art
In general, a video display appliance such as a monitor has a picture adjustment function, with which a user can adjust the brightness, contrast or size of the screen.
The following is a description of a conventional picture adjustment apparatus for a video display appliance made with reference to FIG. 1 . A control section 10 of the video display appliance controls the whole operation of the video display appliance, and processes a user's command inputted through a key manipulation section 20 . The control section 10 also performs the picture adjustment in accordance with the user's command, and provides an on-screen display (OSD) output processing section 30 with OSD data representing the picture adjustment state or result. The OSD output processing section 30 displays the OSD according to the OSD data provided from the control section 10 on a display section 40 . The key manipulation section 20 includes a plurality of keys and interfaces the user and the control section 10 .
The operation of the conventional picture adjustment apparatus as constructed above will now be explained. When a user desires picture adjustment, he/she provides the control section 10 with a command for entering a picture adjustment process by means of the key manipulation section 20 . In accordance with the command, the control section 10 displays a picture adjustment OSD on the screen of the display section 40 . FIG. 2 shows an example of the picture adjustment OSD. The picture adjustment OSD includes a variety of menus that can control the brightness, contrast, size, shape, etc. of the picture. The user can command various kinds of picture adjustment through those menus.
The control section 10 performs the picture adjustment by receiving a picture adjustment command through the picture adjustment OSD, and displays the result of picture adjustment on the picture adjustment menu. Thus, the user can easily confirm the picture adjustment state and the result thereof.
However, the picture adjustment OSD includes a number of picture adjustment menus that are quite difficult to adjust. For instance, it is not only difficult to adjust the shape of the screen, colors, OSD language, removing of wave patterns or color bleeding but also difficult to return them to their original state.
As described above, the conventional apparatus for adjusting the picture of a video display appliance puts the burden of adjusting such difficult picture adjustment menus on the user, and this poses the problems of deteriorating the picture display state due to misadjustment of the picture adjustment menus by an unskillful user or a child, as well as of disabling restoration of the picture display state to the original state.
SUMMARY OF THE INVENTION
It is, therefore, an object of the present invention to provide a picture adjustment method and apparatus for a video display appliance that improves the reliability of the product by preventing unskillful users from accessing picture adjustment menus that are difficult to adjust and return to their original state.
To achieve the above object, there is provided a picture adjustment method for a video display appliance, comprising the steps of: selecting and determining accessible picture adjustment OSDs; if entry into a picture adjustment process is commanded after the determination of the accessible picture adjustment OSDs, displaying the accessible picture adjustment OSDs; if a command for picture adjustment is inputted through any one of the displayed picture adjustment OSDs, checking whether the corresponding picture adjustment OSD is accessible; performing the picture adjustment in accordance with the inputted command for picture adjustment if it is checked that the corresponding picture adjustment OSD is accessible; and ignoring the inputted command for picture adjustment if it is checked that the corresponding picture adjustment OSD is not accessible.
In another aspect of the present invention, there is provided a picture adjustment apparatus for a video display appliance, comprising: a key manipulation section for receiving information on accessible picture adjustment OSDs from a user; a memory for storing information on the accessible picture adjustment OSDs; a display section for displaying various kinds of information; an OSD output processing section for displaying an OSD according to OSD data on the display section; and a control section for providing the OSD output processing section with the OSD data for displaying the picture adjustment OSDs after receiving and storing the information on the accessible picture adjustment OSDs, and processing as an effective command only the command for picture adjustment inputted through the picture adjustment OSD that has been determined to be accessible.
BRIEF DESCRIPTION OF THE DRAWINGS
The above and other objects, features and advantages of the present invention will become more apparent from the following detailed description when taken in conjunction with the accompanying drawings, in which:
FIG. 1 is a block diagram illustrating a schematic construction of a conventional picture adjustment apparatus for a video display appliance;
FIG. 2 is a view illustrating a picture adjustment menu displayed according to the conventional picture adjustment apparatus;
FIG. 3 is a block diagram illustrating a schematic construction of a picture adjustment apparatus for a video display appliance according to a preferred embodiment of the present invention;
FIGS. 4 and 5 are flowcharts illustrating a picture adjustment method for a video display appliance according to the present invention; and
FIGS. 6 and 7 are views illustrating picture adjustment menus displayed according to the preferred embodiment of the present invention.
DESCRIPTION OF THE PREFERRED EMBODIMENT
A preferred embodiment of the present invention will be described herein below with reference to the accompanying drawings. In the following description, well-known functions or constructions are not described in detail since they would obscure the invention in unnecessary detail.
FIG. 3 is a block diagram illustrating a schematic construction of a picture adjustment apparatus for a video display appliance according to a preferred embodiment of the present invention. Referring to FIG. 3 , a control section 100 controls the whole operation of the video display appliance according to the preferred embodiment of the present invention, and processes a user's command inputted through a key manipulation section 102 . The control section 100 provides an OSD output processing section 104 with OSD data for displaying a plurality of picture adjustment OSDs in accordance with the user's command. Each of the picture adjustment OSDs includes a plurality of picture adjustment menus. The control section 100 can display each one of the picture adjustment OSDs in turn in accordance with the user's command.
The control section 100 blocks another user's access to the picture adjustment OSDs that have been selected by a specified user. Here, the specified user refers to a user or managing staff who is capable of easily adjusting picture adjustment menus that are fairly difficult to be adjusted. The specified user may command entry into a menu for determining whether the picture adjustment is accessible. Input of such command may be turning on a power source of the video display appliance in a state that two or more predetermined keys are simultaneously inputted.
Once the picture adjustment is determined to be accessible, the control section 100 displays the picture adjustment OSD determined to be accessible in a black color representing an active state, while displaying the picture adjustment OSD determined not to be accessible in a gray color representing an inactive state. By doing so, the user can easily discriminate the accessible picture adjustment menus from the inaccessible picture adjustment menus.
The OSD output processing section 104 displays the OSD according to the OSD data provided from the control section 100 on a display section 106 . A memory 108 stores various kinds of information, and in particular, information on the accessible picture adjustment OSDs under the control of the control section 100 .
The operation of the picture adjustment apparatus according to the preferred embodiment of the present invention will be explained with reference to the accompanying drawings.
The process of determining the accessible picture adjustment OSDs by the control section 100 will first be described with reference to the flowchart of FIG. 4 . The specified user can command entry into the menu for determining the accessibility of the picture adjustment by turning on the power source of the video display appliance in a state that two or more predetermined keys are simultaneously inputted among the keys of the key manipulation section 102 . Once the specified user commands entry into the menu for determining the accessibility of the picture adjustment (step 200 ), the control section 100 displays any one of the plurality of picture adjustment OSDs on a display section 106 (step 202 ). If the specified user requests the display of another picture adjustment OSD through the key manipulation section 102 after displaying the picture adjustment OSD as described above (step 204 ), the control section 100 displays the picture adjustment OSD requested by the specified user (step 206 ). The picture adjustment OSDs to be displayed are brightness, contrast, colors, position and shape of the screen, language determination, special functions, etc.
If the specified user selects not to display another picture adjustment OSD, step 206 is skipped and control passes to step 208 .
If the specified user inputs information on selecting the accessible picture adjustment while the picture adjustment OSD is displayed (step 208 ), the control section 100 determines whether the corresponding picture adjustment OSD is accessible in accordance with the selected information (step 210 ). The control section 100 stores the determined information in the memory 108 so as to be used whenever displaying the picture adjustment OSD.
Thereafter, the control section 100 determines whether or not the specified user requests termination of the determination of the picture adjustment accessibility by means of the key manipulation section 102 (step 212 ). The control section 100 continuously performs the determination of the accessible picture adjustment OSDs until the command for termination is received.
Here, when selecting the accessible picture adjustment OSD, the specified user determines the picture adjustment OSD including the picture adjustment menus such as brightness, contrast, position of the screen, size of the screen, which are easily retrievable to the original state through manipulation by an unskillful user, to be accessible. The specified user determines the picture adjustment OSD including the picture adjustment menus such as shape of the screen, colors, OSD language, removing of wave patterns or color bleeding, which are not easily reset to the original state through manipulation by an unskillful user, to be unaccessible. Of course, the picture adjustment OSD that has been determined to be accessible can be re-determined to be accessible if necessary.
As described above, once the accessibility of the picture adjustment OSD is determined, the specified user or other users (hereinafter, referred to the “user”) can perform the picture adjustment by using the picture adjustment OSD that has been determined to be accessible.
The process of picture adjustment performed by the control section 100 will now be explained with reference to the flowchart of FIG. 5 . The user may command the picture adjustment by means of the key manipulation section 102 . If the user commands the picture adjustment (step 300 ), the control section 100 displays any one of the plurality of picture adjustment OSDs on the display section 106 (step 302 ). In particular, the control section 100 displays the picture adjustment OSD with a color corresponding to the pre-determined accessibility of picture adjustment. Thereafter, if the user requests a display of another picture adjustment OSD through the key manipulation section 102 after display of the picture adjustment OSD as described above (step 304 ), the control section 100 displays the requested picture adjustment OSD (step 306 ). The picture adjustment OSDs that can be displayed are brightness, contrast, colors, position and shape of the screen, OSD language, special functions, etc. as shown in FIG. 7 . Each picture adjustment OSD is displayed either in black color or in gray color depending on the pre-determined accessibility of picture adjustment. That is, the shape of the screen, colors, OSD language, removing wave patterns or color bleeding, which have been determined to be unaccessible, are displayed in gray color, while the other picture adjustment OSDs are displayed in black color. The control section 100 ignores the command for picture adjustment made through the picture adjustment OSD displayed in gray color to prevent misadjustment of the picture adjustment menus, which are not easily reset to the original state, by an unskillful user.
After displaying the picture adjustment OSD as described above, the control section 100 searches whether or not the user inputs a command for picture adjustment through the key manipulation section 102 (step 308 ). If the user commands the picture adjustment, the control section 100 searches whether or not the corresponding picture adjustment OSD has been determined to be accessible (step 310 ). The control section performs the picture adjustment in accordance with the command for picture adjustment if the corresponding picture adjustment OSD has been determined to be accessible (step 312 ). Otherwise, the control section 100 ignores the command for picture adjustment.
After performing the picture adjustment in accordance with the command for picture adjustment, the control section 100 searches whether or not the user commands termination of the picture adjustment through the key manipulation section 102 [step 314 ]. The control section 100 performs the picture adjustment requested by the user until the user commands the termination of the picture adjustment.
As described above, the present invention has an advantage in that it can improve the reliability of the product by preventing unskillful users from accessing picture adjustment menus that are not easily adjusted and retrieved.
While the invention has been shown and described with reference to a certain preferred embodiment thereof, it will be understood by those skilled in the art that various changes in form and details may be made therein without departing from the spirit and scope of the invention as defined by the appended claims. | Picture adjustment apparatus and methods for a video display appliance, include: a memory for storing information pertaining to at least one apparatus adjustment on-screen display (OSD), the adjustment OSD information including configurable OSD accessibility information, and a control section that processes the stored OSD information. The control section is configured to output OSD data to control display of each OSD, the accessibility of each OSD distinguishable in accordance with the stored OSD accessibility information, wherein an accessible OSD is displayed differently than an inaccessible OSD. | 7 |
BACKGROUND OF THE INVENTION
This invention relates to a separable element which can be severed instantaneously for various purposes. More particularly, it relates to a separable connecting element such as a pyrotechnic bolt-type fastener, which can be fused or melted with little or no noise and provides the capability of utilizing the pressure developed by the resultant heat and products of combustion to perform actuation of a device.
Severable elements which can fasten a plurality of items together, are widely used in connection with space missiles, rocket boosters, multi-stage rockets, commercial vehicles, cranes, ships, submersible mines and valves, and in other applications where instantaneous separation of two or more elements is required. Present explosive devices, and particularly explosive bolts, are subject to the disadvantages that the explosion separating or breaking them is accompanied by noise, shock, production of loose and flying parts and the expulsion of propellant gases into the system or into the atmosphere.
The noise and shock resulting in the escape of propellant by-products from the partially opened severable element is severe enough to disrupt electronic circuits, break communication lines, rupture liquid carrying pipes, causing malfunction or even failure of the device with which the explosive bolt is used. In the case of a flooding valve for a mine or other underwater device the noise produced by the shock waves would be highly deleterious in areas where detection by mine countermeasures would not be desired. The release of gaseous by-products into an ambient environment may also be objectionable in many space, surface and underwater devices as these by-products can contaminate the environs of the device and are capable of building up corrosive by-products on critical items such as wires, tubes, mirrors, electrical control mechanisms and other critical and sensitive elements.
Previous methods which have used detonating chemicals for actuation are typified by U.S. Pat. No. 3,530,759 to Francis, U.S. Pat. No. 3,254,555 to Joneikis, and U.S. Pat. No. 3,200,706 to Kinard. However, the detonating chemicals in Francis represents a safety hazard, particularly during storage, and in Joneikis and Kinard, the generation of actuation noise during detonation of an explosive charge is pronounced and unavoidable. Some methods, e.g., U.S. Pat. No. 3,728,934 to Palmer, have attempted to provide an irreversibly severable linkage which is fused or destroyed by a thermite mixing thus eliminating the use of detonating chemicals. Unfortunately, Palmer does not confine the products of combustion nor does he produce a motive fluid useful for doing work. Also, Palmer's design does not appear to readily lend itself to a system requiring relatively high tensile loads.
A requirement thus exists for a relatively strong low noise level means of quickly separating a fastener on electrical command which can also produce sufficient high pressure gas to perform actuation of a device. The present invention achieves all of these objectives while avoiding the deficiencies of the prior art mechanisms.
SUMMARY OF THE INVENTION
Accordingly, it is an object of the instant invention to provide a new and improved separable connection element.
Another object of the present invention is to provide a new and improved pyrotechnic separation means for actuating a mechanism at a low noise level.
An additional object of the instant invention is to provide a relatively strong pyrotechnic separation device which can quickly separate a bolt type fasterner at low noise levels upon electrical command and additionally supply necessary motive fluid to perform actuation of a device.
A further object of the invention is to provide a pyrotechnic separation device which functions as a low noise level combination gas generator and separation device particularly suited for use as a means of actuating a mechanism such as a flood valve.
Yet another object of the invention is to provide a pyrotechnic separation device which is useful as a silent separation link.
According to one embodiment of this invention a pyrotechnic charge is disposed in a chamber formed in a fusible elongate tubular tensile element. The tensile element has means for attachment to at least two separable items and provides for the electrical actuation of the pyrotechnic charge. The pyrotechnic charge may comprise a combination of an exothermic mixture and a gas producing chemical. In use in a flood valve, a pressure cavity is defined between the valve housing and a sliding member which normally closes intake ports formed in the valve housing. The instant pyrotechnic separation device is fixed at one end to the valve housing and at its other end to the sliding member. Upon valve actuation, the pyrotechnic charge fuses or burns through the fusible elongate tubular tensile element and produces sufficient high pressure gas in the pressure cavity to force the sliding member to uncover the intake ports.
BRIEF DESCRIPTION OF THE DRAWINGS
A more complete understanding of the invention and a fuller appreciation of the many attendant advantages thereof will be derived by reference to the following detailed description when considered in connection with the accompanying drawings wherein:
FIG. 1 is a sectioned view of a preferred embodiment of the pyrotechnic separation assembly of the present invention.
FIG. 2 shows a sectional view of the separation assembly used in an unactuated valve.
FIG. 3 illustrates the valve of FIG. 2 after actuation.
FIG. 4 is an embodiment of the invention used in a silent flooding valve.
FIG. 5 is another embodiment of the invention used as a silent separation link.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring now to the drawings wherein like reference characters designate identical or corresponding parts throughout the several views, and more particularly to FIG. 1 thereof, the instant pyrotechnic separation device, assembly, or bolt is shown as an elongate fusible tubular tensile element or housing 10 of non-uniform cross-section. The bolt is fabricated from a high strength material having suitable thermal and/or combustion characteristics such as glass, graphite, magnesium, aluminum or such materials that lose strength, melt or are combustible. A quantity of a pyrotechnic mixture 12 is disposed within a chamber 14 defined within the tubular housing. An ignition subassembly 16 seals off chamber 14 and comprises an ignition cup 18 fixing a plug 20 and a bridge wire 22 connected to firing cable leads 24. Firing cable leads 24 are encased in a flexible sheath 26 leading to an electrical connector 28 which communicates with a source of electrical energy (not shown). Upon actuation of the pyrotechnic separation assembly, sufficient electrical energy is supplied to bridge wire 22 via leads 24 to cause it to glow red hot and ignite the pyrotechnic mixture.
Arranged about housing 10 is a first means 30 for attachment to a first separable element. Such means could be a circumferential groove seating a retaining ring thereby fixing the housing to the first separable element as will subsequently be seen. Another portion of the bolt, e.g., surface 68 could be used additionally to bear against a surface of the first sparable element. At another end of housing 10, a bolt head 32 is provided for attachment to a second separable element. Bolt head 32 could be a threaded connection, as shown.
As was mentioned earlier a pyrotechnic mixture 12 is disposed within chamber 14. Pyrotechnic mixture 12 is preferably of the types described in the following U.S. patents granted to Helms Jr., et al: U.S. Pat. Nos. 3,695,951, issued Oct. 3, 1972 and 3,503,814, issued Mar. 3, 1970. The most preferred mixture is disclosed in U.S. Pat. No. 3,890,174 issued June 17, 1975 to Helms, Jr., et al. The basic pyrotechnic mixture desired in the present invention therefore will, upon ignition, evolve a great deal of heat and gas capable of doing work. These characteristics are obtained without the generation of noise-producing shock waves typical of detonating chamicals.
A standard array of mixture 12 would include an ignition mix 12a, an easily ignitable mix, which starts burning from a red-hot bridge wire 22. The ignition mix then ignites pyrotechnic mixture 12b which is loose but packed since if it was densely packed it might not light at all. Finally, pyrotechnic mixture 12b ignites compressed increments 12c, 12d of the pyrotechnic mixture which burn through a thin fusible wall 34 in the bolt shank of housing 10. Upon melting of the thin wall 34 the separable elements attached to the housing are released. The gases produced by the preferred pyrotechnic mixture are confined; the separable elements are not just allowed to separate but are in fact forced to separate but without the production of loose parts or a shock wave.
The bolt of FIG. 1 can be used in many areas where high tensile strength is needed despite the presence of thin wall section 34. Tests have shown that a bolt with such a hollow shank retains considerable strength. For instance, an aluminum alloy (e.g., alloy 7075-T6) bolt similar in design to that of FIG. 1 having a 5/16 inch outside diameter shank with a 1/4 inch diameter bore (0.032 inch wall thickness at 34) can have a tensile yield strength of over 1900 pounds.
One example which utilizes the capabilities of the assembly to produce pressure developed by the resultant heat and gaseous products of combustion of the pyrotechnic mixtures to perform actuation of a device is shown in FIG. 2.
FIG. 2 shows a cross sectional view of a pyrotechnically actuated valve before actuation wherein the valve 36 is illustrated installed in a vessel 38, such as a submerged mine or buoy, which is to be subsequently flooded. Pyrotechnic valve 36, preassembled as a complete unit and installed within a receiving bore 40 in vessel 38, is shown to comprise an annular housing 42 having an outwardly extending circumferential flange 44 on its exterior surface bearing upon a supporting ridge 46 formed in bore 40 by a counterbore 48. A retaining ring 50 is received within a recess in bore 48 and engages the flange 44 to securely hold the valve assembly 36 within the vessel 38. An O-ring 52 provides a fluid seal between the valve and the vessel. Housing 42 has a plurality of intake ports 53 to permit fluid entry through the valve 36 after valve actuation.
Nestled within housing 42 is a generally cylindrical sliding member 54 which serves as a translatable obturator for intake ports 53. A center post 56, extending from housing 42, serves to guide sliding member 54 as it translates upon valve actuation. As shown in FIG. 2, member 54 closes off and seals intake ports 53 thereby precluding fluid entry through the valve until valve actuation (see FIG. 3) when fluid is allowed to flow into vessel 38 through ports 53 and thereafter through discharge ports 58, formed in the sliding member. A stop ring 60 limits the extent to which the sliding member can translate for a reason which will presently be understood.
A pressure cavity 62 is defined between an inverted cup 64 formed on a lower extremity of guide post 56 and the cylindrical wall of an interior tube 66 formed within member 54. This tube acts as a bearing surface for the sliding member and cooperates with post 56 in order to guide the translatable sliding member 54 after valve actuation.
Disposed within pressure cavity 62 and fixed at one end to housing 42 and at its other end to sliding member 54, is the pyrotechnic separation assembly or bolt of FIG. 1. Assembly 10 is fixed at end 32, e.g., by a threaded connection with post 56. Abutting surfaces 68 and 70 of assembly 10 and sliding member 54, respectively, in conjunction with a bolt head retaining ring 72 secure the assembly 10 with respect to the sliding member. In this fashion valve 36 is held in its unactuated state by the high tensile strength of the bolt.
Gas seals 74, 76 seal pressure cavity 62 both before and after actuation. O-ring seals 78, 80 lie substantially along the same surface which is equidistant from the centerline of the valve thus thereby making the valve as functionally insensitive to external hydrostatic pressure as the valves described in copending application Ser. No. 826,508 filed Aug. 22, 1977 to Hardesty. Thus, a minimum tensile load is imposed on bolt 10 thereby decreasing the need for bolts capable of resisting extremely high tensile loads.
Upon valve actuation, electrical energy is supplied bolt 10 through leads 24 to the bridge wire 22 causing same to glow red hot and eventually ignite the above-described pyrotechnic mixture incorporated in the bolt 10. The pyrotechnic charge initiated by the electrical means is enabled to quickly (less than a second) burn and/or melt the thin wall 34 of the bolt shank causing the bolt head 32 to be separated from the remainder of the bolt shank of the assembly 10, as shown in FIG. 3.
Inasmuch as stop ring 60 limits the extend to which sliding member 54 is allowed to translate upon valve actuation (see FIG. 3) and since gas pressure seals 74 and 76 maintain the integrity of pressure cavity 62, any high pressure gases developed due to the combustion of the pyrotechnic mixture are confined within cavity 62. Thus, upon valve actuation when the pyrotechnic mixture 12 burns through thin wall 34, the high pressure gas confined within cavity 62 tends to force the sliding member away from the valve housing 36. It is noted that while production of loose parts during actuation is minimized due to the bolt fuzing process, any potential loose parts produced due to any random event are confined within the pressure cavity. Retaining ring 72 holds bolt 10 in a locked position even after valve actuation, as shown in FIG. 3.
FIG. 4 depicts a silent flooding valve in cross section which incorporates a modified embodiment of the present pyrotechnic separation device wherein a wall 82 of a submerged container or vessel to be flooded is provided with a receiving bore 84 holding a quantity of noise dampening fluid 86 such as silicone grease between an annular rubber grease retainer 88 and a fusible diaphragm cup 90. The silicone grease also provides better thermal insulation than the liquid being held out. Of course if the outside medium is air or an inert gas, no insulation would be required. Retainer 88 is secured within bore 84 by a retaining ring 92 fixedly received within a groove formed in a counterbore 94. Diaphragm cup 90 has a flange 96 fitted within counterbore 98. A modified annular pyrotechnic separation device 10' abuts a back-up ring 100 which contacts flange 96. A retaining ring 102, which abuts a lower surface of separation device 10', is threadedly secured in wall 82 and holds the entire assembly in place. Sealing means such as O-ring 104 prevents the loss of fluid 86.
As shown in FIG. 4 pyrotechnic separation device 10' is configured as an annular, upwardly facing container holding a sufficient quantity of the pyrotechnic mixture 12. The mixture is contiguous to the outer peripheral wall of the diaphragm cup 90 at a point called the separation zone 105. Zone 105 extends 360° around the diaphragm cup and is the zone which will be fused by the pyrotechnic mixture. A dual firing circuit characterized by electrical initiator 106 provides the necessary means for remotely actuating the valve.
Upon valve actuation, electrical initiator 106 ignites the pyrotechnic charge in separation device 10' thereafter causing a melting of the peripheral wall of cup 90 in the separation zone. Due to the fusing of the metal of cup 90, the diaphragm cup is incapable of resisting the hydrostatic pressure acting upon the rubber grease retainer 88. The external fluid thus forces the grease and the remainder of cup 90 into the vessel. However, substantially no noise is produced by the valve since the pyrotechnic mixture or charge produces no noise and, where needed, the silicone grease adds a further dampening effect.
Turning now to FIG. 5, a silent separation link 160 is shown as having a fusible tensile element such as a tie rod 108 fixedly secured as, e.g., by swaged fittings 110 to housings 112 and 114. Attachment means 107 allow link 160 to be used as a separable fastener between two temporarily connected elements (not shown). Interdisposed between housings 112 and 114 is a pyrotechnic charge holder 116 which surrounds rod 108. Contiguously surrounding rod 108 and located within a chamber 118 in holder 116 is a quantity of pyrotechnic material 120. Passages formed by clearances 122 lead from chamber 118 to pressure chambers 124 which are sealed by O-rings 126. Both housing 112 and 114 have cylindrical walls 138 and 140 extending therefrom which interdigitate with cylindrical walls 142 and 144, having a smaller radius, extending from charge holder 116 in order to form pressure chamber 124.
Actuation energy for the link is provided by a firing circuit cable 128 having the prerequisite electrical initiator 130 which communicates with ignition mix 132 and loosely packed pyrotechnic mix 134. Seal 136 prevents combustion gas escapage. Upon actuation, pyrotechnic charge 120 melts tensile element 108 tending to allow the temporarily connected elements to separate. Aiding this separation process is the pressure experienced in pressure chambers 124 produced by the gas generating chemical in the pyrotechnic charge.
The link thus separates without the generation of noise inasmuch as charge 120 creates no shock wave due to detonation. Furthermore, the silent separation link is highly reliable due to the use of dualized pressure chambers 124. The redundancy of the use of the pressure of the combustion gases ensures that the elements desired to be separated are in fact separated.
There has thus been disclosed an improved means which is a combination gas generator and separation device having multifurious uses in which low noise level, no production of loose parts, loss of combustion products can be precluded, high reliability and rapidity of operation are requirements. Another distinct advantage is that the handling, loading and testing of pyrotechnic materials is less hazardous when compared to high explosives and sensitive detonators.
Obviously, numerous modifications and variations of the present invention are possible in the light of the above teachings. It is therefore to be understood that within the scope of the appended claims the invention may be practiced otherwise than as specifically described herein. | A combination gas generator and pyrotechnic separation device which causes separation of elements safely, quietly, quickly, and without the production of loose parts or release of combustion gases to the ambient environment. A tubular tensile element houses a quantity of pyrotechnic material which, when ignited, burns, fuses or melts a tensile element allowing the separable elements to break apart. High pressure gases generated by the combustion of the pyrotechnic material aids in separating the separable elements. | 5 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a method for compression molding powder and a powder compression molded article made thereby. More particularly, it is concerned with a method for compression-molding powder to produce a molded article composed of a plurality of different material layers which are disposed in a compression direction, and a powder compression molded article produced thereby.
2. Description of the Prior Art
In powder metallurgy, mechanical parts having improved properties are produced at a low cost by using two kinds of powders.
Functional parts and structural members are generally produced by a method which comprises compression-molding powder into a predetermined form and firing or sintering the powder mold thus formed. This method is desirable and advantageous because the powder can be readily molded into any desired shape. Resin molded articles and sintered metal parts are produced by such powder compression molding methods. Generally, two layers consisting of different powder materials are arranged along the direction parallel to the pressurizing direction as described in Japanese patent publication no. sho-55-1961 and Japanese laid open application (OPI) No. sho-47-27814. Alternatively, two layers are arranged along the direction perpendicular to the pressurizing direction as disclosed in U.S. Pat. No. 2,753,858.
According to these methods, two kinds of powders are filled within the same die so that two powder layers can be subject to simultaneous pressure molding (compacting) to thus reduce production steps. However, in case complicated composite layers are to be molded as shown in U.S. Pat. No. 2,753,859, prior pressurization (compacting) of one of the powder layers is required.
In order to eliminate this additional process step, simultaneous pressure molding has been proposed wherein two kinds of powder materials are filled in the same die to integrally provide pressure molding and to provide a molded article having a complicated structure as disclosed in Japanese patent publication nos. 51-39166 and 54-31963. However, according to these methods, a plurality of lower punch means are required so that the punching means is weak in mechanical strength and complicated to operate. In addition, the mechanical wear of these punch means may degrade the dimensional accuracy of the resultant molded product.
As indicated, in powder compression molding, particularly in the production of functional parts, different materials are compression-molded in a multi-layer form to produce a molded article having special characteristics. This multi-layer construction is usually employed for the purpose of reducing material costs by using a special metal material or some other kind of special material for a predetermined layer or layers and an ordinary metal material or some other kind of ordinary material for the other layers. For example, in the case of a valve seat for use in an internal combustion engine, a composite sintered alloy is often used. The composite sintered alloy is composed of a high-alloyed sintered material and a low alloy sintered material. The high alloyed sintered material has good abrasion and corrosion resistance and is located on a valve spot surface of the valve seat and the low-alloyed sintered material forms the remaining portions of the valve seat. A composite material is also used when making resin parts for seals or bearings. The sliding surface of the resin part is made of a corrosion resistant or oil resistant material having a low coefficient of friction and the remainder of the resin portion is made of an ordinary material.
Such multi-layer powder compression molded articles have heretofore been produced most generally by a method and press machine shown in FIGS. 1(a) to (d). The press machine has a die 2, a lower punch 3, an upper punch 5 (FIG. 1(c)), a first feed shoe 6 (FIG. 1(a)) and a second feed shoe 7 (FIG. 1(b)). To produce an article according to the conventional method, a first powder A is introduced through the first feed shoe 6 by raising the die 2 relative to the lower punch 3 or lowering the lower punch 3 relative to the die 2. Then a second powder B is introduced through the second feed shoe 7 by again raising the die 2 relative to the lower punch 3 or lowering the lower punch 3 relative to the die 2. Thereafter, powder compression molding is effected with the upper punch 5 and the lower punch 3.
This method produces a valve seat as shown in FIG. 2(a ) and a resin seal ring 9 as shown in FIG. 3(a), each having a zone 81 or 91 made of a special material having specific desired characteristics.
The method shown in FIGS. 1(a)-1(d) inadequately reduces the volume of the special material required to produce the desired molded article and therefore does not adequately reduce the material costs.
In order to remove the foregoing defects in the abovementioned Japanese Patent Publication No. 39166/1976, a method is disclosed comprising the steps shown in FIGS. 4(a) to (d) using a press machine having a lower punch which comprises an inside lower punch 3A and an intermediate lower punch 3B. To make a molded article using this press machine, the inside lower punch 3A is first lowered to introduce a first powder A through a first feed show 6 and then the intermediate lower punch 3B is lowered to introduce a second powder B through a second feed shoe 7. Afterwards, an upper punch 5 is lowered to effect powder compression molding. This method permits one to obtain multi-layer powder compression molded articles as shown in FIG. 2(b) and FIG. 3(b) having only a part of the cross-section, i.e., the zone 81 or 91, made of the special material. However, as pointed out above, press machines having the above described double structure lower punches are mechanically weak in strength. Furthermore, when the inside lower punch and the intermediate lower punch do not fit in each other, satisfactory powder compression cannot be achieved and this impairs production stability. Also, since the lower punch comprises two punches 3A and 3B, the lower punch becomes complicated to operate and troubles often occur.
SUMMARY OF THE INVENTION
Accordingly, an object of the present invention is to provide a multi-layer powder compression molded article having a plurality of different material layers disposed in a compression direction.
A further object is to provide a method for compression molding powder to produce a multi-layer powder compression molded article which requires that a reduced amount of a special material be used.
A yet further object is to provide a method of making such molded articles which is simplified, has fewer working steps, and is excellent in production.
The present invention, therefore, relates to a powder compression molding method for producing a multi-layer powder compression molded article having a plurality of different materials disposed in a compression direction by utilizing relative movements of an upper punch, a lower punch, a die, two feed shoes and/or a core rod. More specifically, the method of the present invention comprises the steps of:
(1) forming a first space by means of the die and/or the core rod, and the lower punch, at least one of the die and the core rod being provided with a step in a compression direction,
(2) introducing a first powder into the first space by means of a first feed shoe,
(3) lowering the lower punch to form a second space so that the upper surface of the first powder on the step of the die or core rod and the upper surface of the first powder on the lower punch is slanted and falls continuously in a powder compression direction,
(4) introducing a second powder into the second space, and
(5) compressing the first and the second powders.
The article of the present invention is a powder compression molded article which has a plurality of different material layers disposed in a compression direction wherein the boundary between the different material layers is slanted. The height of the boundary along a direction perpendicular to the compression direction is similar to a part or whole of the rest curve of the first powder layer.
BRIEF DESCRIPTION OF THE DRAWINGS
FIGS. 1(a) to (d) show a series of working steps, in cross-section, illustrating a conventional powder compression molding method for producing molded articles as shown in FIGS. 2(a) and 3(a).
FIGS. 2(a) and 2(b), 3(a) and 3(b) are cross-sectional views of conventional powder compression molded articles;
FIGS. 4(a) to (d) show a series of working steps, in cross-section, illustrating a conventional powder compression molding method for producing the molded articles as shown in FIGS. 2(b) and 3(b);
FIGS. 5(a) to (f) show a series of working steps, in cross-section, illustrating an embodiment of the method of the present invention;
FIGS. 6(a) to (f) show a series of working steps, in cross-section, illustrating another embodiment of the method of the present invention;
FIG. 7 shows a press machine having a core rod with a step formed therein;
FIG. 8 is a cross-sectional view of an embodiment of the molded article of the invention;
FIG. 9 is a cross-sectional view of another embodiment of the molded article of the invention; and
FIG. 10 is a cross-sectional view of yet a further embodiment of the molded article of the invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
The powder compression molding method of the invention comprises the working steps shown in FIGS. 5 or 6.
According to the method of the present invention, at least one of a die 2 (FIGS. 5 and 6) and a core rod 4 (FIG. 6) has a step 21 (FIGS. 5 and 6) and/or 41 (FIG. 7) in a compression direction.
The molding method of the invention can be summarized as follows:
1st Step: (FIGS. 5(b) and 6(b)) A first powder A is introduced through a first feed shoe 6 into a first space 31 including an intrinsic space 30 defined by a die step between a die 2 and a lower punch 3 and into a space 31 formed by relative downward movement of a lower punch 3.
2nd Step: (FIGS. 5(c) and 6(c)) The lower punch 3 is lowered relative to the die 2 to form a second space 32 so that the top surface A1 of the first powder positioned above the step 21 or 41 of the die 2 or core rod 4 and the top surface A2 of the first powder positioned above the lower punch 3 describes a curve which falls gradually along a direction perpendicular to a compression direction.
3rd Step: (FIGS. 5(d) and 6(d)) A second powder B is introduced into the second space 32 through a second feed shoe 7.
4th Step: (FIGS. 5(e) and 6(e)) The first and second powders A and B are compression molded.
One embodiment of the method of the invention comprises the steps shown in FIG. 5 and another embodiment of the invention comprises the steps shown in FIG. 6.
Specifically, the method shown in FIG. 5 comprises the following six steps:
1st Step: (FIG. 5(a)) A die 2 is raised or a lower punch 3 is lowered to form a first space 31. The first space 31 includes an intrinsic space 30 defined by the step 21 of the die 2, the die 2 and the lower punch 3. The top of the lower punch 3 can be above or below the step 21.
The exact position of the lower punch 3 relative to the step 21 depends on the desired thickness of the first powder layer A and the desired thickness of the second powder layer B.
2nd Step: (FIG. 5(b)) A first powder A is introduced into the space 30, 31 through a first feed shoe 6.
In this step, the suction caused by the relative movement between the die 2 and the lower punch 3 can be utilized to introduce the first powder A into the first space 30, 31 by placing the first feed shoe 6 at a suction charging point prior to performing the first step. Alternatively, after the first step, charging can be performed.
3rd Step: (FIG. 5(c)) The die 2 is raised or the lower punch 3 is lowered to form a second space 32 above the top surface of the first powder A.
In this step, the top surface A1 of the first powder A positioned above the die step 21 is held at nearly the same height as the top surface of the die 2. However, the top surface A2 of the first powder positioned above the lower punch 3 is lowered by the relative downward movement of the lower punch 3. When the relative downward movement of the lower punch 3 is finished, a portion of the first powder A above the step 21 flows downward toward the lower punch. Thus, the top surface of the first powder A forms a curve. The shape of this curve can be controlled by controlling the distance the lower punch 3 is lowered and by controlling the speed of descent of the lower punch.
4th Step: (FIG. 4(d)) A second powder B is introduced into the second space 32 through a second feed shoe 7.
In this step, in order to prevent the top surface of the first powder A from collapsing and thus changing its shape, the second feed shoe 7 should be placed at a charging point after the 2nd step is completed. Thereafter, the lower punch 3 can be lowered to form the second space 32 and simultaneously the second powder B can be introduced into the second space 32 by the second feed shoe 7.
5th Step: (FIG. 5(e)) The upper punch 5 is lowered relative to the die 2 and the lower punch. In addition, after the upper punch 5 is lowered or while it is lowered, the lower punch 3 is raised relative to the step 21 to effect powder compression molding.
In this step, if the lower punch 3 is raised or the die 2 is lowered before the upper punch 5 reaches the top surface of the powder A, B, the powder A, B will overflow the top surface of the die 2. Therefore, the lower punch 3 should be raised relative to the step 21 simultaneously with or after the lowering of the upper punch 5. Furthermore, after the upper punch 5 reaches the top surface of the powder A, B, it is desired to compress the powder A, B between the upper punch 5 and the lower punch 3 by moving each of these punches 3, 5 at relatively equal speeds in order to obtain a uniform powder compression molded density. It is therefore desirable to operate the lower punch 3 or die 2 simultaneously with the upper punch 5.
Some functional parts or molded articles used in special applications have a structure wherein the layers A, B are parallel to each other in the compression direction. In producing powder compression molded articles having the foregoing structure, it is desirable that the die 2 be lowered after the upper punch 5 is lowered to the top surface of the powder. In addition, in some cases it is desired that the bottom surface of the step 21 of the die 2 be made level with the top surface 33 of the lower punch 3 by lowering the upper punch 5 and raising the lower punch 3, and when the level position is achieved, the operation of te die 2 or lower punch 3 is stopped and only the upper punch 5 is further lowered to complete the powder compression molding. By this procedure, the deviation between the amount of powder B above and below the step after the powder A, B is compressed is reduced and the formation of interfacial stress is easily minimized.
6th Step: (FIG. 5(f)) The die 2 is lowered relative to the lower punch 3 to remove the powder compression molded article 1.
In this case, when the step 21 is long in the powder compression direction and the direction perpendicular thereto, the friction between the inner surface 23 of the die 2 and the powder compression molded article 1 causes the formation of strains and cracks in the powder compression molded article 1. Therefore, the length in the powder compression direction and the direction perpendicular thereto of the step 21 is inevitably limited. This limited length is determined by the density and coefficient of friction of the powder and the height of the powder in the powder compression direction. It is desirable to increase the length of the step 21 to a relatively high level by providing a fine draft to the inner peripheral surface of the die 2.
The second method of the invention comprises the working steps shown in FIGS. (6(a) to (f). This method is different from the foregoing method shown in FIGS. 5(a) to (f) in that the second method uses a press machine which has a core rod 4. In other respects the second method is basically the same as the first method.
A powder compression molded article obtained by the second method is usually in the form of a ring. The point or points where the step 21 and/or 41 is provided varies depending on which section of the inner peripheral surface of the ring is to be made of the specific powder material B or which section of the outer peripheral surface of the ring is to made of the specific powder material B.
In the former case where a section of the inner peripheral surface is to be made of the specific powder material B, the step 21 is formed on the inner surface of te die 2. In the latter case where a section of the outer peripheral surface is to be made of the specific powder material B, the step 41 is formed on the outer surface of the core rod 4. If both the inner and outer peripheral surfaces of the ring are to be made of the specific powder material B, steps 21 and 41 are formed in both the die and the core rod.
Although the above description has been made with reference to the foregoing first and second methods, the present invention is not limited thereto. Referring to FIG. 5(e) or FIG. 6(e) for example, the lower punch 3 can be placed at a point higher than the top surface 22 of the step 21 to produce a molded article having a projection in the bottom thereof. On the other hand, the lower punch 3 can be placed at a point lower than the top surface 22 of the step 21 to produce a molded article having a recess in the bottom thereof. Of course, the shape of the lower punch 3, the upper punch 5 and the top surface 22 of the step should be appropriately selected so as to have a shape corresponding to the desired shape of the molded article.
The method of the invention can be carried out by the use of a molding press machine having a simplified structure. The press machine only requires an upper punch, a lower punch and a die. This simplified structure minimizes operating and maintenance problems, reduces accidents, and reduces the number of required working steps in forming the molded article. Thus the method of the invention is excellent for producing molded articles. Furthermore, since the thickness of the second powder layer B made of the specific material can be changed, it is possible to reduce the volume of the specific material which is required.
The present invention further relates to a powder compression molded article which can be easily made using the method of the invention as described hereinbefore.
The powder compression molded article of the invention has a boundary between the first powder layer and the second powder layer the shape of which is very similar to the rest curve of the first powder layer with one or both ends of the molded article being the vertex or vertexes of the boundary line.
Referring to FIG. 8, a powder compression molded article 1 of the invention is made of a multi-layer composite material comprising a first powder layer 11 and a second powder layer 12. There is almost no second powder layer 12 at an end 13 of the powder compression molded article 1. The boundary 10 between the first powder layer 11 and the second powder layer 12 gradually falls toward the other end 14 of the molded article 1 thereby defining a curve which is similar to the rest curve of the first powder 11. Therefore, the second powder layer 12 is thick at the end 14 of the powder compression molded article 1 and the second powder layer exists in a nearly triangular zone with the edge 14 of the second powder layer being a vertex of the triangular zone.
The powder compression molded article of the invention, when provided with a second powder layer 12 constituting a top surface 15 and a side surface 16, is very useful as a functional part.
Another embodiment of the powder compression molded article of the invention is a valve seat as illustrated in FIG. 9.
Referring to FIG. 9, a second powder layer 12 is formed in such a manner that it contains only a sliding surface 80 and an inner peripheral surface 82 where a heat load is high. Furthermore, the sliding surface 80 has a uniform depth. Therefore, as compared with the conventional molded articles, the layer B required for the valve seat of the present invention is much less than that required in the valve seats shown in FIGS. 2(a) and (b). The valve seat shown in FIG. 9 can be produced by compression molding the powder A, B in a rectangular form as indicated by the dotted line in FIG. 9 and then maching the molded product into the desired article shape shown by the solid line in this Figure. Alternatively, the powder can be compression molded into the ultimate article shown by the solid line in FIG. 9.
The article shown in FIG. 8, can be easily produced by the method of the invention shown in FIG. 5. However, it can be produced by other methods as well.
A third embodiment of the molded article of the invention is a thrust bearing 95 shown in FIG. 10. In the thrust bearing 95, a boundary 90 between a first powder layer 96 and a second powder layer 97 is highest at both ends 93 and lowest at a central point 94. The boundary 90 describes a curve similar to the rest curve of the first powder layer 96. A sliding surface 99 indicated by the dotted line is formed by working or is formed during powder compression molding. The second powder layer 97 made of the special material forms the sliding surface 99 and, therefore, the volume of the second powder layer can be minimized. The third embodiment of the molded article of the invention is produced, more preferably, by the method shown in FIG. 5 wherein a step 21 is provided on the entire inner periphery of the die 2. This molded article can be produced by other methods as well. Thus the invention is not limited to the methods of production as described hereinbefore. A projection 98 shown in FIG. 9 can be produced by the method shown in FIG. 5 wherein during the step (e) the lower punch 3 is stopped at a point lower than the top surface 22 of the step 21 and the powder compression molding is effected with the upper punch 5.
As described above, the molded article of the invention has a boundary between the first powder layer and the second powder layer which is similar to the rest curve of the first powder layer. Therefore, when it is used as a composite material for use in a special application, the volume of the second powder layer can be reduced and the second powder layer can be uniformly provided in the critical zone.
The molded article of the invention is not limited to the first to third embodiments as described above. For example, a powder compression molded article as shown in FIG. 10 can be used as a seal ring whose rip portion is made of the second powder and as a tappet for use in an internal combustion engine.
The powder compression molded article of the invention can be used after sintering and firing and in some cases may be subjected to post treatments such as infiltration, impregnation, sulfurization, nitrization and hardening. | A powder compression molding method for producing a multilayer powder compression molded article having a plurality of different material layers disposed in a compression direction utilizes relative movements between an upper punch, a lower punch, a die having a step formed therein, and two feed shoes. The powder compression molded article thus formed requires a reduced amount of a special layer. The powder compression molding method includes forming a first space by moving the die relative to the lower punch, introducing a first powder into the first space through a first feed shoe, lowering the lower punch relative to the die to form a second space so that an upper surface of the first powder on the step of the die and on the lower punch has a nonuniform height, introducing a second powder into the second space, and moving the upper punch towards the lower punch to compress the first and second powders. | 1 |
This invention relates to a recirculating document feed device and more particularly, to a device which includes a pivoting portion containing no prime movers and a method for aligning documents despite slippage in document moving roll nips.
BACKGROUND OF THE INVENTION
Paper moving schemes appearing in the art are numerous and include such devices as vacuum belts, vacuum trays, wave generators, large diameter rollers, soft high friction rollers, hard high friction rollers, and leading edge pullers. Means of moving, turning, or transporting said devices include chains, belts, blowers, etc. driven by a prime mover such as a motor.
In recirculating document feed devices, a document is passed through a processing station and then recirculated so that it passes through the processing station again. The cycle can be repeated any number of times until the desired number of processing steps have been completed. Recirculating document feed devices ordinarily use paper moving schemes involving gears and belts, etc. such as described above and as illustrated in U.S. Pat. No. 3,661,383. Such systems are subject to difficult document retrieval should a jam occur, they are costly relative to the invention to be described herein, and are difficult to adjust and maintain.
The instant invention involves a configuration in which it is possible to drive an entire system of paper moving devices by providing only one set of driven rolls directly connected to a prime mover and using frictional contact between those rolls and additional sets of freely rotating rollers to obtain document recirculation. The freely rotating rollers are positioned in a pivoting frame which opens to expose the document feed path to provide for ease of document retrieval, ease of mechanism adjustment, ease of maintenance and easy book copying. This arrangement provides a reliable low-cost drive which is quiet and safe because of its freedom from belts, chains, or gears. This is also important from a safety viewpoint since recirculating document feed devices are in an area of user access.
An additional advantage of the invention is the ability to bias the side of a moving document against a side reference edge with a controlled force so as not to crumple the edge of the document by making use of the principles described in U.S. Pat. No. 4,179,117. In an especially innovative and advantageous design, the invention incorporates a large freely rotating roller which forms a part of two roll nips in two different document feed paths and thus creates unusual problems in document side edge referencing in both paths. The invention herein solves that problem.
Additionally, the beam strength of documents when driven around the substantially 180° bends of a recirculating document feed path creates slippage in roll nips and therefore unusual problems in maintaining alignment of the document against the side reference edge. Moreover, a document in two roll nips may be pulled through one nip by the other, again creating an unusual aligning problem. The invention herein provides a method for solving these problems.
SUMMARY OF THE INVENTION
This invention is embodied in a document feed device which includes a first set of roll nips provided in a first document path, the roll nips comprised of driven rolls and a first set of freely rotating rollers. The driven rolls are placed on the underside of the first document path protruding slightly above the plane of the path to individually mate with individual ones of the first set of freely rotating rollers which are thereby powered through contact with the driven rolls. A reference edge is provided along one side of the document feed path to provide a surface for referencing documents. The drive rolls and the first set of freely rotating rollers are skewed to the direction of document travel to urge documents against the reference edge.
The document feed device further includes a second document path for receiving documents from the exit of the first path and returning them to the entrance of the first path. The second document path contains a second set of roll nips comprised of two groups of freely rotating rollers. The first group of freely rotating rollers is situated on the underside of the second document path and each roller protrudes slightly into the plane of that path to mate individually with individual ones of the second group of freely rotating rollers. The second group of freely rotating rollers are powered through contact with the first group of freely rotating rollers which are powered ultimately by contact with the driven rolls. The first and second groups of freely rotating rollers are skewed to the direction of document travel in the second path to urge documents into a second reference edge positioned along one side of the second document feed path.
The document feed device contains a movable cover portion mounted about a pivot to expose the first document feed path, thus breaking the first set of nips when opened. When opened, none of the freely rotating rollers can operate since the only source of power is connected to the drive rolls which are not a part of the movable portion.
In a particular embodiment, large rollers are provided to form a part of both the first and second set of roll nips, that is, the large roller mates with a drive roll to form one of the first set of nips in the first document path and also extends into the second document feed path to mate with a roller of the second group of freely rotating rollers to form one of the second set of nips. In this embodiment, the driven rolls are skewed between zero and 0.4 degrees for urging a document away from the first reference edge, while the first set of freely rotating rollers, the large rollers are skewed between zero and 0.6 degrees for urging documents toward the first reference edge. The coefficient of friction of the first set of freely rotating rollers may be chosen to be greater than the coefficient of friction of the drive rolls.
In this particular embodiment, by virtue of the fact that the first set of freely rotating rollers protrude into both document feed paths and urge the document toward the reference edge in the first document feed path, it moves the document away from the second reference edge in the second document feed path. The second group of freely rotating rollers, therefore, should have an angle of skew and a coefficient of friction relative to the first set of rollers such that a proper alignment of the document is maintained in the second path. This requirement is met in the described embodiment in an unusual manner since the coefficient of friction of the roller urging the document toward the reference edge is substantially lower than the coefficient of friction of the mating roller. This method of arranging the rollers is advantageous due to slippage of the document in the roll nip during document movement toward the reference edge and allows the document to follow the lower friction roller when slippage is occurring on the higher friction roller. This results since the document, when slipping, will follow the roller on the nondriven side of the nip.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows a recirculating document feed device containing the instant invention positioned on a small compact copier machine.
FIG. 2 is a schematic diagram showing the recirculating paper path of the embodiment of FIG. 1, together with the major elements of the copier machine.
FIG. 3 shows the document feed device of FIG. 1 pivoted to an open position exposing the lower document feed path.
FIG. 4 is a perspective drawing of a partial sectional view of FIG. 2 showing the skewing arrangement of drive rolls and freely rotating rollers in order to urge document alignment with the reference edges.
DETAILED DESCRIPTION
The document feed device of this invention is useful in many environments but is illustrated in this detailed description in conjunction with a document copier machine in order to explain its features and its value.
FIG. 1 shows a document copier machine with an exterior housing 10 containing a top surface 11 inclined at an angle of approximately 20° to the horizontal. Positioned on that top surface is a document feed path 19, the sides of which are generally defined by reference edge 13 and spine 14. Document feed path 19 forms a part of a recirculating semiautomatic document feed device (RSADF) 15 together with hinged cover 15' and all associated drive rolls, freely rotating rollers, and guides. When cover 15' is closed as shown in FIG. 1, cover 15' and document feed path 19 provide an entry slot 12 for the insertion of single documents to be copied. After copying, these documents exit from the RSADF through an exit slot 17 located in cover 15'.
A paper cassette 35 is shown in place for feeding copy paper into the machine. The completed copy is returned against the face 40 of the cassette.
FIG. 2 is a schematic drawing showing the interior side view of the copier machine of FIG. 1 illustrating the document path 18 of the recirculating semiautomatic document feed device 15. FIG. 2 also shows the copy paper path 36 from cassette 35 and the various processing stations located along photoconductive belt 20.
A document to be copied is manually inserted through input slot 12, where it is sensed and driven to queuing gate 44. If no other document is being copied, gate 44 is released allowing the document to advance to registration gate 46. When the machine is ready, gate 46 is released allowing drive rolls 48 and 50 to move the document across the fiber optic viewing station 16. The original document, after processing, is either delivered to the exit slot 17, or is recirculated for multiple copies by return paper path 18 as determined by the position of gate 63. Gate 63 is automatically positioned in accordance with the number of copies selected by the operator and a count of the number of copies already produced from that original document.
The image of the original document thus scanned is placed upon a continuous loop photoconductor (PC) belt 20, which is retained in place by means of a guide frame assembly 21.
The copier machine shown in FIG. 2 takes an electrophotographic two-cycle process configuration wherein corona 25 operates as a charge corona to place an appropriate electrostatic voltage level on PC belt 20. The image of the original document is placed upon belt 20 at imaging location 26 by selective discharge, based upon the information contained in the original document. This image is then developed by developer unit 30 which places toner on appropriate areas of belt 20 as it passes the magnetic brush roller 31.
The paper gating mechanism 34 controls the introduction of copy sheets from cassette 35 to the photoconductor belt 20 in appropriate synchronism with the movement of the toned image on belt 20. Corona 24 operates as a transfer corona to transfer toner from belt 20 onto the copy sheets. The copy sheets continue to the fuser comprised of rollers 38 and 39 where the toner image is fused to the copy sheet. The toned copy sheet is then exited from the machine.
FIG. 3 shows the machine of FIG. 1 with the cover 15' of the recirculating document feed device 15 rotated around the hinges 41 to an open position. In this position, the entirety of the document feed path 19 along the top surface 11 is exposed to view. FIG. 3 shows document feed path 19 with a document reference edge 13 along one side and a spine or rail guide means 14 positioned along the opposite edge. Entry sensor 42, aligner roll 43, queuing gate 44 and registration gate 46 precede viewing station 16 in paper feed direction A. All document moving rolls protrude above the plane of top surface 11 with rolls 45, 47, 48, 49 and 50 lying within path 19 and rolls 52, 53 and 54 located across the rail guide means 14 outside of the document path.
The open cover 15' in FIG. 3 shows the corresponding rollers 43', 47', 48', 49' and 50' which mate with the rolls on the top surface 11 to form roll nips when the cover 15' is closed. The open cover in FIG. 3 also exposes a manual start button 51 for use when copying books.
When a single sheet is to be copied and document feed cover 15' is in place, entry switch 42 automatically starts machine operation when the document is sensed, and aligning roll 43 operates to position the single sheet against reference edge 13 and queuing gate 44. After alignment, and if there is no preceding sheet in the device 15, gate 44 is dropped and mating rolls 43 and 43' move the paper down the feed path 19 in direction A to registration gate 46. At the proper point in the machine cycle, gate 46 is dropped allowing rolls 43, 47 and 48 to move the document across a stationary elongated document viewing station 16, the major dimension of which is perpendicular to feed path direction A. Rolls 49 and 50 continue to move the document out through exit slot 17 or around through the return paper path 18 if multiple copies are to be made.
If multiple copies are being made, the sheet recirculates through document path 18 shown in FIG. 2 until it returns to gate 46. Again, at the proper point in the machine cycle, gate 46 will drop initiating another copy sequence. During this period of recirculation, a next sheet can be inserted by hand to aligning roll 43 and moved against the queuing gate 44. In that manner, once the required number of copies have been made of the first document and it has exited through slot 17, gate 44 will drop allowing the second document to proceed to gate 46 and repeat the cycle.
Rolls 45, 52, 53 and 54 together with spine 14 are provided for copying books as more fully explained in U.S. patent application Ser. No. 296,683.
A comparison of FIGS. 1 and 3 show that the document feed device 15 contains a lightweight, easily movable cover portion 15' pivoted by hand to an open position by grasping cover 15' at hand grip 60. This ease of movement is made possible by the fact that none of the rollers mounted in the pivoting cover 15' are driven except through contact with the drive rolls when the cover is closed. As may be observed in FIG. 3, this provides an added safety feature since none of the rollers 43', 47', 48', 49' or 50', which are exposed when the cover 15' is open, are driven when the machine is used for copying a book along the exposed paper path 19.
Referring now to FIGS. 2 and 4, the drive mechanism for recirculation of documents is illustrated. Drive rolls 48 and 50 are positioned on the underside of first document feed path 19 protruding slightly through the plane of that path to form a first driving nip with freely rotating rollers 48' and 50'. In the embodiment illustrated, the latter rollers are large in circumference and extend upwardly to protrude slightly into second document feed path 18 to form a second nip with freely rotating rollers 48" and 50". Exactly the same construction is present for roller groups 49, 49', 49" and 47, 47' and 47" so that the groups of rollers form sets of nips, a first set of nips in document feed path 19, and a second set of nips in second document feed path 18.
A drive motor 62 is shown in FIG. 4 connected to drive roll 48. Suitable connecting transmissions, not shown, connect motor 62 with the other drive rolls. Motor 62 may also drive other components within the copier machine if desired. It should be noted that in the embodiment shown in FIGS. 1-4, the nonpivoting portion of document feed device 15 is a part of the copier machine itself, that is, the first document feed path 19 is coincident with the top surface 11 of the copier machine 10.
In operation, a paper is fed by hand through entry slot 12 and after queuing at gate 44 and registering at gate 46 as previously described is fed into that portion of document feed path 19 containing the rollers 47 and 48. These rollers with the associated freely rotating rollers 47' and 48' move the document across viewing station 16 and into the nip of rollers 49, 49', and 50, 50'. If multiple documents are to be made, the document is recirculated into the second document feed path 18 where the document is fed in direction B through the rollers 50', 50" and 49', 49" and into the nips of rollers 47', 47" and 48', 48". The leading edge of the paper is then fed around bend 61 and back into first paper path 19 to register against gate 46 prior to beginning the next cycle.
As may be appreciated, it is important to maintain proper document position against reference edge 13 while the document passes across the viewing station 16. As a consequence, rollers 48 and 48' are skewed to direction A, that is, the direction of document movement along paper path 19 so that the paper is urged toward reference edge 13. FIG. 4 shows that roller 48' is positioned at an angle such that it tends to drive the paper toward reference edge 13 while roll 48 is skewed to direction A in a manner such that it tends to urge the document away from reference edge 13. In a preferred embodiment, roller 48' is positioned at an angle between zero and 0.6 degrees into the reference edge, while the drive roll 48 is positioned at an angle between zero and 0.4 degrees away from the reference edge. One can be assured that the document will be moved toward the reference edge if roller 48' is caused to have a higher coefficient of friction than roll 48. The advantage of skewing roll 48 to urge the paper away from the reference edge is that this provides control over the force moving the paper into the reference edge and thus prevents a crumpling of the paper when it engages with edge 13. It should be understood that once the document edge is aligned against the reference edge, slippage in the roll nip must occur to keep the document from crumpling and thus control over the forces moving the document into the reference edge is important. Again, that subject is fully discussed in above-referenced U.S. Pat. No. 4,179,117.
As one can appreciate from FIG. 4, when large roller 48' is positioned to urge paper toward reference edge 13 in paper path 19, it results in moving paper away from reference edge 13' when the paper is moving in second document feed path 18. Thus, freely rotating roller 48" is skewed to the direction of document movement B to urge the documents towards reference edge 13'. Again, by choosing the coefficient of friction of roller 48" to be greater than roller 48', one can be assured of moving the paper toward reference edge 13'. However, in a preferred embodiment of this invention, roller 48" is chosen to take a lower coefficient of friction than roller 48' for the following reasons. As paper is moved around bend 61, the beam strength of the paper tends to cause a high drag force in the nip of rollers 48', 48" which tends to create slipping in the roll nip. When slipping, the document tends to follow the roller on the nondriven side of the nip and thus the leading portion of the document is correctly positioned against the reference edge by skewing roller 48" toward the reference edge. This is advantageously accomplished by a low friction roller since it is important to limit the force moving the document into the reference edge once the document is against the reference edge. Slippage between the document and the roller on the nondriven side of the nip must occur at that point to avoid crumpling the document.
When the leading edge of the document has passed around bend 61 and enters the nip of rolls 48 and 48', it tends to be pulled through the nip of rollers 48' and 48" thus again creating slippage at that nip. As a result of that slippage, the document again tends to slip on roller 48' which is on the drive side of the nip (although not itself directly driven) and to follow the lower friction roller 48" on the nondriven side of the nip. Thus the trailing portion of the document is correctly positioned against reference edge 13' and the low coefficient of friction of roller 48" prevents document crumpling at the reference edge.
In a preferred embodiment, roller 48' is positioned between zero and 0.6 degrees in a manner tending to urge the paper away from the reference edge in the second paper path 18 while freely rotating roller 48" is skewed at an angle between 1° and 15° to the direction of paper movement tending to urge the document toward the second reference edge 13'. A representative coefficient of friction may be 0.6 to 1.5 for roller 48' and 0.4 or less for roller 48". A similar analysis can be made for rollers 47' and 47".
Thus, a recirculating document feed device has been described which requires no driven components in a hinged cover and in which documents are successfully aligned against reference edges for accurate copying even though slippage is present in roll nips while the document is being moved toward the reference edge. There are modifications to the embodiments described which might be made at one's discretion. For example, the single large rollers 47', 48', 49' and 50' could be replaced by a plurality of rollers and various skewing arrangements might be attempted with different device dimensions and/or configurations.
While the invention has been particularly shown and described with reference to a preferred embodiment thereof, it will be understood by those skilled in the art that the foregoing and other changes in form and details may be made therein without departing from the spirit and scope of the invention. | A document feed device, illustrated with a copier machine, for recirculating documents through a processing station. A movable portion of the document feed device is mounted for pivoting movement to expose a lower document feed path. The movable portion contains several document moving rollers but no prime movers, gears or belts; these rolls are driven by frictional contact with each other and ultimately by contact with a set of driven rollers located in the nonmoving portion of the document feed device. The rollers comprising a document moving nip are oppositely skewed relative to the direction of document travel in order to move documents gently toward a reference edge and coefficients of friction of roller materials are chosen to insure correct document alignment. | 1 |
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