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This is a continuation of U.S. application Ser. No. 08/199,107, filed Feb. 22, 1994, now abandoned.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The invention relates to devices and methods for changing fluid flow resistance in a conduit and more particularly to devices and methods for variably changing fluid flow resistance in a fluid flow control device by changing the geometry of the device at entrance and discharge portions of a narrow part of the device.
2. Description of Related Technology
The fluid flow resistance in a line system may be increased by increasing frictional resistance in a conduit defining a cavity through which fluid flows by utilizing a fluid control device which substantially changes the size of a cross-section of the cavity. Such a control device may be a flexible element which is inserted into the conduit. With respect to the direction of flow of a fluid through a conduit, such a state of the art flow control device may provide an unbroken (i.e. continuous) reduction of the cavity cross-sectional area up to a narrowest cross-section and then gradually widen the cavity in a continuous, unbroken manner. Control devices of this type find application in various known devices such as membrane valves and tube clamps.
A drawback to control devices of this type is that they exhibit a small flow amplification factor (i.e., the change in the flow resistance resulting from the change of cross-sectional area of a conduit is small). For this reason, a very narrow cavity cross-section (i.e. small gap width) is necessary to produce even a small fluid flow controlling effect. This may be undesirable, for example, when a solid-containing fluid, such as a pulp suspension, flows through such a device in a paper machine because there is a considerable danger of blockage. Furthermore, such devices may increase the possibility of the formation of fiber agglomerations or clumps.
SUMMARY OF THE INVENTION
It is an object of the invention to overcome one or more of the problems described above. In particular, it is an object of the invention to influence the flow of fluids, such as a pulp suspension, in a conduit and provide an extremely large flow amplification factor in a small operating region, such as a headbox of a paper machine. It is also an object of the invention to utilize small changes in the geometry of a flow control device to change flow resistance while avoiding blockage and the formation of fiber flocs or clumps.
A method according to the invention for variably controlling fluid flow in a closed flow line having an arbitrary cross-sectional form includes passing fluid through a fluid control conduit having first and second conduit portions each having a discrete cross-sectional profile. A transition edge is disposed between the first and second conduit portions. The fluid flow resistance is adjusted in the fluid control conduit by changing the contour of the transition edge.
A device according to the invention includes at least two connected conduits which define a cavity through which fluid flows. Each conduit has a discrete substantially constant cross-sectional profile whereby a transition step is formed between the first conduit and the second conduit. The transition step defines an edge which can be adjusted between a sharp and a rounded contour.
Other objects and advantages of the invention will be apparent to those skilled in the art from the following detailed description taken in conjunction with the drawings and the appended claims.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a partially schematic sectional view of a flow control device according to the invention showing P1≡P2.
FIG. 2 is a partially schematic sectional view of the flow control device of FIG. 1 showing P2 >>P1.
DETAILED DESCRIPTION OF THE INVENTION
Unlike some of the known prior art fluid control devices, a device and method according to the invention does not influence fluid flow resistance in a pipe by changing the wall friction of a control element disposed in the pipe. Rather, according to the invention, a flow cavity of a pipe is narrowed or widened in an abrupt or broken manner (i.e. a discontinuous fashion) and small contour changes are made to the radius of an edge disposed at a narrow portion of the cavity. These small geometrical adjustments produce significant differences in the fluid flow resistance at entrance and discharge locations of the device.
Entrance and discharge fluid flow resistances can be calculated utilizing the continuity form of the Bernoulli equation and the momentum theorem for ideal, sharp-edged non-continuous cross-sectional area changes as follows:
ζ.sub.in =(A.sub.2 /A.sub.0 -1).sup.2 (1)
ζ.sub.out =(A.sub.3 /A.sub.2 -1).sup.2 (2)
where
ζ in is entrance resistance;
ζ out is discharge resistance;
A 0 is a cross-sectional area of a contracted fluid jet;
A 2 is a cross-sectional area of a fluid control device cavity at a contracted location; and
A 3 is a cross-sectional area of a pipe cavity subsequent to the control device (with respect to the direction of fluid flow).
Experiments as well as theoretical considerations have shown that the entrance and discharge fluid flow resistance at a discontinuous narrowing or widening of a pipe corresponds to equations (1) and (2) above only when an edge defined by a transition step between pipe sections of discrete cross-sectional profiles has an infinitely small edge radius R. Furthermore, the flow resistance decreases significantly for small changes of R. Thus, when a transition edge is flattened slightly (i.e. the edge radius R is increased), the effective flow cross-section A 0 changes very considerably in relation to the change of the edge radius R. Therefore, a large effect on the change of the resistance ζ in results. The invention utilizes this effect by exercising an influence on the edge radius R by suitable means, as will be further described herein. As a result, effective changes in fluid flow resistance are produced with slight changes in the geometry of the fluid control device.
The inventive device and method are advantageous because the change of geometry of the device necessary to vary fluid flow through a system is so small that the inventive device may be utilized to control flow throughputs, especially the headboxes of paper machines. For this reason, the problem of pulp suspensions forming fiber flocs or clumps, for example, at gaps and recesses in the head box can be eliminated. Furthermore, a device according to the invention requires little space, making it desirable for use in a turbulence insert of a paper machine.
Additionally, because a device and method according to the invention requires almost no mass movement to change the contour of a transition edge of a flow conduit, it is possible to provide very flexible and fast-reacting automatic control of fluid flow resistance in a pipe.
FIG. 1 shows a variably adjustable flow control device, generally designated 10 according to the invention including a flow conduit or pipe 12 having a diameter D1 and the direction of fluid flow shown by an arrow 14. The pressure in the pipe 12 is P1. The pipe 12 defines a cavity 16 which changes from the diameter D1 to a smaller diameter D2. The two resulting cross-sectional profiles of the pipe cavity are discrete and each profile is preferably substantially constant. A pressure region 18 having outside pressure P applied thereto to result in a pressure region pressure designated P2 is disposed at an opposite side of the cavity 16 and is defined by a pipe portion 20 having the diameter D2 and a transition step 22. The transition step 22 and the pipe portion 20 define a transition edge K1. In a region of the step 22 and the pipe portion 20 adjacent to and including the edge K1, the pipe wall thickness is highly reduced and elastic.
A mirror image of the step 22 is shown at an exit or discharge portion 26 of the pipe cavity 16 where the pipe 12 widens from the diameter D2 to the diameter D1 with a thin-walled transition edge designated K2.
As shown in FIG. 1, the pressure P2 in the region 18 is approximately equal to the pressure Pl in the pipe 12. For this reason, edges K1 and K2 retain their original sharp-edged form and therefore induce a relatively high fluid flow resistance.
On the other hand, FIG. 2 shows the same embodiment of the invention with the exception that the pressure P2 in the area 18 is very much larger than the pressure P1 inside the pipe 12. As a result, the thin-walled edges K1 and K2 deform, so that edges K1 and K2 are highly rounded. Due to the large radius of curvature of the edges K1 and K2 as shown in FIG. 2, the edges exert a small induced resistance. Therefore, the total fluid flow resistance of the flow control device is reduced correspondingly.
Alternative embodiments according to the invention are possible in which, for example, the pressure region P2 is divided into front and back pressure regions so that the shape of the front edge K1 can be adjusted independently of the back edge K2 and vice versa.
In another embodiment, several successive transition edges are provided at a flow entrance region of the device, the edges protruding into the fluid flow and being rounded to various degrees by corresponding individual application of pressure thereon. In this way incremental induced resistance changes and the desired result may be achieved.
The foregoing detailed description is given for clearness of understanding only, an no unnecessary limitations should be understood therefrom, as modifications within the scope of the invention will be apparent to those skilled in the art. | An apparatus and method for variably controlling fluid flow in a closed flow line, especially the flow of a pulp suspension through a headbox of a paper-making machine, includes guiding fluid through a cavity of a conduit having at least two different cross-sectional profiles. Fluid flow resistance is adjusted by changing the contour of an edge defined by the conduit and a transition step connecting the two cross-sections. | 3 |
TECHNICAL FIELD
[0001] The invention relates to a heating system and a method of controlling a heating system. The heating system may be advantageously used as part of a vehicle seat heating system.
BACKGROUND OF THE INVENTION
[0002] There are known methods and systems for controlling electric seat heaters in which the heating mechanism is operated by a control of temperature as a function of a user input. Such control systems are suitable for setting an optimal comfort temperature, but respecting their control they require a comparatively large structural outlay. There are also simpler controls based on a timer function. Here, at the start of seat heating, a target time is assigned, after transgression of which the seat heating is switched off. The disadvantage of such a timer based control is that the timer times are either not variable, or comprise a variability only to the effect that the on-duration depends on the seat temperature.
[0003] DE 101 06 152 A1 discloses a method of controlling a stationary ventilator in a motor vehicle. A timer assigns a target time for an on-duration of the ventilator when the inside temperature exceeds a preassigned limit. The ventilator is switched on and off with an on-duration and an on-frequency so long as the inside temperature is above the preassigned limit. On-duration and on-frequency of the ventilator are determined as a function of the inside temperature of the vehicle.
[0004] DE 100 58 434 A1 describes a method and device for control of the heating of an outside mirror, the heating output being controlled as a function of a variation of the outside temperature per unit time.
[0005] JP 58194612 A, lastly, describes a control device for a vehicle heater that is part of a vehicle air conditioning system. To control the seat heating, various input quantities, such as an outside temperature, a battery voltage and a water temperature of a vehicle cooling system are processed.
[0006] Accordingly, there exists a need for an improved vehicle seat heating system and a control method for the same.
SUMMARY OF THE INVENTION
[0007] The present invention provides a simple method of controlling a heating mechanism, and a control device of simple structure for a heating mechanism, in which a demand control of the heat output is made possible.
[0008] In one embodiment, a method of controlling a heating mechanism, in particular an electric seat heater for a motor vehicle, provides a variation of a target time for a duration of heating as a function of a difference between a measured outside temperature and a measured inside temperature. The inside temperature may be a measured temperature in or on a seat of a motor vehicle. The method according to this embodiment has the advantage of a very low circuitry and structural outlay, yet a demand control of the heat output is made possible. This is accomplished in that for variation of a target time for an on-duration of the heater, not only is the outside temperature taken into account, but in like manner the inner or seat temperature influences the on-time of the heating. According to measured seat temperatures, a shorter or longer heat duration may be appropriate. The known methods, in contrast, take only an outside temperature to preassign or vary on on-duration or output of the heater.
[0009] The difference of the outside temperature (T A ) and inside temperature (T I ) may in particular be derived by determination of a quantity called the sensory temperature (T E ) and calculated. The sensory temperature may be derived from a function of the outside temperature and the difference between the outside temperature and the seat or inside temperature, and may be represented in principle by the following formula:
T E =f[T A , ( T A −T I )] (1)
where T E is the sensory temperature, T A the outside temperature and T I is the inside temperature which may be the seat temperature, T S . In this way, the human sensation of temperature differences is better taken into account, so that the measured difference of outside and inside, or seat temperature, is not converted linearly into the variation of target time for the duration of heating. Instead, a function is formed that leads to a demand or sensory variation of the heat duration, as a function of the difference between inside and outside temperatures.
[0011] One embodiment of the method according to the invention provides at least two fixedly set heating stages, each with a different target time, referred in each instance to one and the same difference between an inside and an outside temperature, or to the same sensory temperature. Alternatively, however, a plurality of heating stages may be provided. Further, an additional variation of the heat output, stepwise or continuous, may be provided.
[0012] The outside temperature may advantageously be queried and determined by way of a data bus. Normally, in a conventional vehicle outfit, the outside temperature is already available, so that the values of the outside temperature sensor can be queried by way of central control electronics or by way of a data bus in the vehicle (e.g. “CAN-Bus”). The inside temperature, or seat temperature, can then be queried by way of an inside temperature sensor or by way of a seat temperature sensor. For this purpose, in particular, a negative temperature coefficient (NTC) sensor may be used. The inside or seat temperature may be queried likewise by way of an inside temperature sensor used as part of an air conditioning system of the vehicle. The signal for the inside temperature can likewise be made available by way of the same data bus as the outside temperature.
[0013] The preassigned target time for the duration of heat may be converted according to the selected heat stage into a corresponding correction factor, so that for a greater adjusted heating stage, a different correction of the target time for the on-duration of the heating is assigned than for a smaller adjusted heating stage.
[0014] The target times for the heat duration and their corrections may be derived in particular from a vehicle-specific and/or a seat-specific characteristic. For example, the seat may include a fan which may dictate a different heating profile than a non-ventilated seat. In this way, an optimal coordination of various sensory temperatures with corresponding target times for the on-duration can be set up. The heat output for the heating mechanism may in particular be adjusted by variation of voltages and/or by way of a pulse-width modulated signal. The characteristic curves may be stored, according to vehicle type or seat variant, as play-back software in the control unit or in the control circuit. In this way, like control circuits may be employed for the several vehicle and seat variants. The characteristic curves may be played back e.g. by way of so-called “flashes.” Here, the control unit is suitably programmed by playing the correspondingly provided software over programmable memory circuits.
[0015] A heating system according to the invention for a heating mechanism, in particular for an electric heating device of a vehicle seat, provides an outside temperature sensor and an inside or seat temperature sensor as well as a way of preassigning and/or varying a target time for a heating duration as a function of a difference between a measured outside temperature and a measured inside temperature. The heating mechanism may in particular comprise at least two fixedly adjusted heating stages, each with a different target time, referred in each instance to a like difference between inside and outside temperature.
[0016] Other features, embodiments and advantages of the control device according to the invention have already been mentioned in terms of the several variants of the method previously described.
[0017] The present invention itself, together with further objects and attendant advantages, will be best understood by reference to the following detailed description, taken in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0018] For a more complete understanding of this invention reference should now be had to the embodiments illustrated in greater detail in the accompanying figures and described below by way of examples of the invention wherein:
[0019] FIG. 1 shows a schematic diagram of a control device according to one embodiment of the invention;
[0020] FIG. 2 shows an example of a characteristic diagram for controlling a target time as a function of measured temperatures in accordance with an embodiment of the invention;
[0021] FIG. 3 shows a running diagram of a method according to an embodiment the invention; and
[0022] FIG. 4 shows an exemplary environment of the present heating system.
DETAILED DESCRIPTION OF THE INVENTION
[0023] In the following figures, the same reference numerals will be used to refer to the same components. While the present invention is described with respect to an apparatus for a vehicle seat heating system, the present invention may be adapted and applied to various systems including: electrical systems, heating systems, seating systems, vehicle systems, or other systems known in the art.
[0024] In the following description, various operating parameters and components are described for one constructed embodiment. These specific parameters and components are included as examples and are not meant to be limiting.
[0025] FIG. 1 illustrates, in a schematic diagram, the structure of a heat system according to one embodiment of the invention. The outside temperature T A is acquired by way of an outside temperature sensor 10 . The seat temperature T S is acquired by way of a seat temperature sensor 12 . The two sensor signals are processed in a control circuit 14 to adapt a target time t soll in a target time transmitter 16 to the on-time and/or the heat output of the heating mechanism 20 .
[0026] The heating mechanism 20 may be a resistive heating element comprising conductive wires, filaments or fabric. It can be an areal heating element, for example, disposed proximate a vehicle seat cushion surface such as the seating surface or back rest. Other types of heating elements may also be employed.
[0027] The controller 14 may be implemented in hardware or software. For example, it can be a control circuit or it can be implemented in a controller comprising a CPU, inputs, outputs and associated memory. The controller can be stand-alone controller or be part of another vehicle controller such as the HVAC system controller. Also, although the controller 14 and target time transmitter 16 are shown as separate components, they could be integrated into a single unit.
[0028] The outside temperature T A may be part of an existing vehicle sensor outfit, so that the sensory value is already available in a data bus of the vehicle (for example, CAN-Bus 18 ). For example, many vehicle HVAC systems include or make use of an outside temperature sensor for vehicle interior climate control.
[0029] The seat temperature sensor 12 may in particular be an NTC sensor on or near the seat. For example, it may be located underneath the seating surface to provide a seat surface temperature. It could also be located underneath the seat or near a surface away from the occupant to provide an ambient temperature output. Alternatively, or in addition to seat sensor 12 , an inside temperature sensor 11 may be employed to provide a temperature signal indicative of the ambient vehicle interior temperature (T I ). Again, such inside temperature sensors 11 are typically employed in vehicle HVAC systems. In such a case, its data signal may be made available to the controller 14 by way of a vehicle data bus 18 .
[0030] FIG. 2 shows an example of a characteristic diagram for variation of a target time t soll for the on-time of the heating as a function of a difference between seat (T S ) or inside (T I ) and outside temperature (T A ). Here, it becomes clear that in a first heating stage (“Low”), a shorter on-time t soll-1 is provided for given temperature difference, whereas on a second heating stage (“High”), a longer on-time is provided for given temperature difference. According to temperature difference or sensory temperature T E , the on-time varies continuously in both stages.
[0031] From the diagram, it becomes clear that with increasing sensory temperature (T E ), a continuous decrease of the on-time of the heating mechanism is provided. This decrease in on-time takes account of the fact that when the seat is already warmer, a shorter heating time of the seat is required to reach a given temperature. For a correspondingly colder seat, a longer heating time is desirable.
[0032] The anterior portion of the curves represents a maximum on-time for both heating stages. The sensory temperature T E-0 is lowest here, and in the example of the sketch is equal to −40° C. The on-time t soll-1 at the lower heating stage (“Low”) may here for example be about 10 minutes. The on-time t soll-2 at the higher heat stage (“High”) may for example be about 20 minutes.
[0033] The intermediate range of the curves represents an intermediate on-time for both heating stages. The sensory temperature T E-1 is located at the so-called working point, and in the embodiment sketched by way of example is 0° C. The on-time t soll-1 at the lower heat stage (“Low”) may here for example be about 4 to 5 minutes. The on-time t soll-2 at the higher heating stage (“High”) may for example be about 8 to 10 minutes.
[0034] The posterior range of the curve represents a minimal on-time for both stages. The sensory temperature T E-2 is here greatest, and in the example of the sketch is about +40° C. The on-time t soll-1 at the lower heat stage (“Low”) may here be about 1 to 2 minutes. The on-time t soll-2 at the higher heat stage (“High”) may here be about 3 to 5 minutes.
[0035] Intermediate values can be determined by continuous shifts of the given values for the temperatures. The characteristic field of FIG. 2 may be stored in memory within the control circuit 14 or in the target time transmitter 16 . Optionally also, a simplified control may be provided, in which there is no continuous adjustment of target times, but adjustment in a number of steps.
[0036] FIG. 3 shows a flow diagram to illustrate the mode of operation of one method according to the invention. After the start, it is queried in a first step S 1 whether the heating device is switched on or off (On?). If the answer is affirmative (Y), then in a second step S 2 the preassigned heating stage is queried. In the case of two heating stages, these may for example be a “Low” stage and a “High” stage. In a third step S 3 , an outside temperature T A is queried. As noted above, the outside temperature T A can be provided by way of the vehicle communication bus 18 from an outside temperature sensor 10 . In a fourth step S 4 , a seat temperature T S or an inside temperature Ti is queried. These values are provided, for example, from the seat temperature sensor 12 or vehicle interior temperature sensor 11 , and may be communicated directly or by way of the vehicle communication bus 18 . From the two temperature values T A and T S , or T A and T I , in a following step S 5 a sensory temperature T E is computed. From the calculated sensory temperature and the preassigned heat stage, in a following step S 6 a target time t soll is computed for an on-time of the heating mechanism 20 , and forwarded to the heating controller 14 . This ensures that the heating mechanism 20 is being operated at a preselected heating stage during the calculated time.
[0037] It is contemplated further that a time sequence of a plurality of different heat stages may be provided. For example, with very low outside temperature, this may be first a stage with short, vigorous heating, following by a longer lasting stage with reduced heating. On the other hand, if the outside temperature is not so low, for example a heating stage with intense heating may be followed first by a pause and then by a shorter heating stage with reduced heating compared to the warm-up phase.
[0038] FIG. 4 shows a schematic diagram of one exemplary embodiment of the present heating system and control method in a vehicle seat application. In this example, at least one vehicle seat 24 of the vehicle 22 includes one or more heating elements 20 . The heating elements 20 are shown in both the seat and backrest cushions of the vehicle seat 24 , but could be in one or the other as desired. The controller 14 , as shown, is disposed within the vehicle seat 24 , but could also be located elsewhere in the vehicle as described above. The controller 14 is in electronic communication with the heating elements 20 , either directly or by way of the target time transmitter 16 or vehicle communication bus 18 . The controller 14 receives outside (T A ), inside (T I ) and seat (T S ) temperature values from the respective sensors 10 , 11 , 12 , either directly or by way of the communication bus 18 . Also, although both seat sensor 12 and interior sensor 11 are shown, only one or the other may be desired for the particular vehicle application.
[0039] While the invention has been described in connection with one or more embodiments, it is to be understood that the specific mechanisms and techniques which have been described are merely illustrative of the principles of the invention, numerous modifications may be made to the apparatus described without departing from the spirit and scope of the invention as defined by the appended claims. | A method of controlling an electric heating system for a motor vehicle seat, in which a target time (t soll ) for a heating duration is varied as a function of a difference between a measured outside temperature (T A ) and a measured inside temperature (T I ). A control device for a heating mechanism ( 20 ) is also provided having an outside temperature ( 10 ) and an inside temperature sensor or seat temperature sensor ( 12 ), and having a control circuit for preassigning and/or varying a target time (t soll ) for a heat duration, as a function of a difference between a measured outside temperature (T A ) and a measured inside or seat temperature (T I or T S ). | 7 |
This invention relates generally to orthopedic knee braces, and more particularly to knee braces for use by persons having anterior cruciate ligament laxity or insufficiency to protect them from injury due to abnormal anterior tibial movement.
BACKGROUND OF THE INVENTION
Various types of knee braces are shown in the patent literature and are commercially available. The following constitute examples of prior art braces that deal with restricting anterior movement of the tibia: U.S. Pat. Nos. 4,9055,369 (Bledsoe et al.); 5,433,699 (Smith, III); 4,751,920 (Mauldin et al.) and 4,781,180 (Solomonow). The apparatus shown by Mauldin is a knee brace that has a first attachment portion to attach the brace to the wearer's thigh and a second attachment portion to attach the brace to the wearer's tibia and a hinge connected to the medial side of the first and second attachment portions by way of a thigh bar and tibia bar, respectively. An adjustable gearing mechanism located at the hinge permits the wearer to limit the amount of rotation of the tibia bar with respect to the thigh bar. However, this brace suffers from failing to be able to prevent anterior translation of the tibia by the application of posterior pressure directed at the tibia tubercle location. Instead, like its predecessors, the Mauldin apparatus attempts to limit tibial rotation by limiting medial hinge motion.
The apparatus shown by Solomonow is a knee brace having an upper framework attached to the thigh and a lower framework attached to the lower leg just below the knee. These two frameworks are hinged on the medial and lateral sides of the leg (bilateral hinge). A bell crank is pivotally connected to the lower framework. An adjustable screw coupled to one side of the bell crank engages an offset portion of the upper framework whenever the leg is extended. The other side of the bell crank is coupled to a tibial restraining strap. As the leg is extended, the lower framework and bell crank are rotated counterclockwise until the offset of the upper framework contacts the screw, rotating the bell crank in a clockwise direction and thereby tightening the tibial restraining strap against anterior movement of the tibia.
The apparatus shown by Bledsoe et al. is a knee brace which also utilizes bilateral hinges to connect the thigh support and calf support sections. The bilateral hinges basically comprise adjustable drive plates that alternate the pivoting point of the thigh support and calf support throughout leg flexion and extension. By varying the pivot point at different points throughout leg extension, a counter shearing force is generated to reduce the shearing force created by the quadriceps muscle which cause the undesirable anterior shift of the tibia of the leg.
Other prior art knee braces are disclosed in U.S. Pat. Nos. 3,581,741 (Rosman); 5,277,698 (Taylor); 5,512,039 (White); 3,387,305 (Shafer); 4,240,414 (Theisler); 4,805,606 (McDavid, III); 4,961,416 (Moore et al.); and U.S. Pat. No. 4,854,308 (Drillio).
Examples of prior art knee braces which are commercially available are: Innovative Sports C.Ti., C.Ti. 2 , C.Ti. 2 Lite, Edge, Edge Lite, Sentry, C180 and MVP all of which are sold by Innovation Sports, Inc. Of Irvine, Calif.; Cincinnati ACL which is sold by Brace Technologies, Inc. Of Cincinnati, Ohio, the OS-5 (TM) non-custom functional knee support which is sold by Omni Scientific, Inc. Of Martinez, Calif.; the Lennox Hill (TM) OTS Brace and Spectralite Brace which are sold by 3M Health Care of Long Island City, N.Y.; the SKO (TM) and TKO (TM) knee orthoses which are manufactured by Orthotic Consultants of Southern California; the ACL model knee brace which is sold by Townsend Design of Bakersfield, Calif.; the DONJOY 4-Point (TM), Gold-Point (TM), Playmaker (TM), and Defiance (TM) all of which are sold by Smith & Nephew Donjoy, Inc. of Carlsbad, Calif; the Poli-Axial Osteoarthritis Brace which is sold by Generation Orthotics, Inc.; and, the ECKO (TM) II Extension Control Knee Orthosis which is sold by Orthomedics of Brea, Calif.
While the aforementioned patents seem suitable for their intended purposes, it would be a significant advance in the art to provide a knee brace assembly that applies posterior pressure on the wearer's tibia in response to extension of the wearer's leg through the use of a cross-strap that is positioned over the wearer's tibia, wrapped in crisscross manner behind the wearer's knee and attached to biased strap guides slidably mounted to the brace assembly.
OBJECTS OF THE INVENTION
Accordingly, it is a general object of this invention to provide a knee brace assembly which overcomes the disadvantages of the prior art.
It is a further object of this invention to provide a knee brace assembly for restricting anterior movement of the wearer's tibia.
It is a further object of this invention to provide a knee brace assembly for restricting abnormal anterior tibial movement without preventing the wearer from being able to fully extend his/her leg.
It is a further object of this invention to provide a knee brace assembly that is inexpensive to manufacture.
It is a further object of this invention to provide a knee brace assembly that is reliable in operation.
It is a further object of this invention to provide a knee brace assembly that is simple in construction.
It is a further object of this invention to provide a knee brace assembly that is lightweight.
It is a further object of this invention to provide a knee brace assembly that is comfortable when worn.
SUMMARY OF THE INVENTION
These and other objects of this invention are achieved by providing a knee brace assembly for restricting anterior tibial movement. The knee brace assembly includes a proximal cuff for engaging the wearer's leg above the knee and a distal cuff for engaging the wearer's leg below the knee. The proximal and distal cuffs are linked together by a hinge means that permits pivotal rotation of the proximal cuff relative to the distal cuff. The proximal cuff has lateral and medial portions each having a slot extending there along. A strap guiding means is slidably mounted within each of the slots. Each strap guiding means is arranged to slide between a proximal extreme when the wearer's leg is in flexion and a distal extreme as the wearer extends his or her leg. A biasing means biases each strap guiding means towards its proximal extreme. A cross-strap, having free ends and a length, is provided for engagement with the wearer's leg. The cross-strap attaches to the wearer's leg below the knee and wraps behind the knee in crisscross fashion. The free ends of the strap attach to the strap guiding means. The cross-strap is operative in response to extension of the wearer's leg to pull the strap guiding means from the proximal extreme towards the distal extreme thus creating a force counteractive to abnormal anterior movement of the tibia.
DESCRIPTION OF THE DRAWINGS
Other objects and many attendant features of this invention will become readily appreciated as the same becomes better understood by reference to the following detailed description when considered in connection with the accompanying drawings wherein:
FIG. 1 is an isometric view of a first embodiment of the present invention;
FIG. 2 is an enlarged sectional view taken along line 2--2 of FIG. 1;
FIG. 3 is an enlarged sectional view taken along line 3--3 of FIG. 1;
FIG. 4 is an enlarged sectional view taken along line 4--4 of FIG. 3;
FIG. 5 is a sectional view taken along line 5--5 of FIG. 1;
FIG. 6 is a sectional view taken along line 6--6 of FIG. 1;
FIG. 7 is an exploded isometric view of a first embodiment of the present invention;
FIG. 8 is an isometric view of a second embodiment of the present invention;
FIG. 9 is an enlarged sectional view taken along line 9--9 of FIG. 8;
FIG. 10 is an enlarged sectional view taken along line 10--10 of FIG. 8;
FIG. 11 is an enlarged view of an area shown in FIG. 10 encircled by a line labeled FIG. 11;
FIG. 12 is an enlarged sectional view taken along line 12--12 of FIG. 10;
FIG. 13 is a sectional view taken along line 13--13 of FIG. 8; and, FIG. 14 is an exploded isometric view of a second embodiment of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring now in greater detail to the various figures of the drawings wherein like reference numerals refer to like parts there is shown at 20 in FIGS. 1, 5 and 7 a first embodiment of the dynamic orthopedic knee brace assembly of the present invention. As shown in FIGS. 1 and 5, the knee brace assembly 20 is shown attached to a human left leg 25 (shown in phantom) having a thigh portion 30, a knee 35 and leg portion below the knee 40. The left leg 25 is chosen for convenience only and the brace assembly 20 can be affixed to either the right or left leg. Generally speaking, the knee brace assembly 20 functions to counteract anterior shifting of the tibia when the anterior cruciate ligament in the illustrated leg is missing or damaged. Such anterior shifting of the tibia occurs for a variety of reasons and often occurs when a person is engaging in physical activities that involve sudden turning to the right or to the left, sudden stopping, jumping, running backwards or other types of movement. Where the anterior cruciate ligament is missing or damaged, such anterior shifting of the tibia can also occur when a person simply extends his or her leg from a flexed position towards its fully straightened position (FIGS. 1 and 3). Referring now to FIG. 7, the knee brace assembly 20 of the present invention comprises three basic parts: a bracing component 45, a cross-strap 50 and a sleeve 55. The bracing component 45 comprises an upper or proximal cuff 60, which is engageable with a wearer's thigh, a distal cuff 65, which is engageable with the wearer's leg portion below the knee 40, and a pair of polycentric hinges 70 which pivotally join the cuffs 60 and 65 together. Straps, used for securing the cuffs to the wearer's leg, are shown generally at 75 and 80.
Referring now to FIGS. 1 and 7, the bracing component 45 is constructed to fit a wearer's leg as will become apparent hereinafter. The upper or proximal cuff 60, is formed to fit the anterior portion of the wearer's leg above the knee, and is essentially curvilinear in configuration and shaped to fit over the wearer's thigh 30. The proximal cuff 60 has medial and lateral depending portions 90 and 95, respectively, and a front arcuate portion 85 (FIG. 1). The proximal cuff 60 is open at the posterior portion so that it may be placed over the thigh 30 from the anterior or front. The distal cuff 65 is similar in construction to the proximal cuff in that it is curvilinearly shaped and formed to fit the anterior portion of the wearer's leg portion below the knee 40. It also includes a front arcuate portion 100, a medial depending portion 110 and a lateral depending portion 105.
The proximal and distal cuffs 60 and 65 and the polycentric hinges 70 are made of lightweight, high impact thermoplastic material which can be formed to fit the contours of the individual wearer's leg. The cuffs 60 and 65 may be fabricated from any suitable material, e.g., carbon fiber filament, carbon fiber filament and polymer composite, carbon/titanium composite, woven carbon fiber infused with acrylic resin. Preferably, the cuffs 60 and 65 are fabricated from a material that is water resistant and non-corrosive to enable the wearer to use the knee brace assembly in a full range of activities including working, walking, running, vigorous athletics and high-impact sports including fresh-water and salt water sports.
Referring now to FIGS. 6 and 7, the proximal cuff 60 is padded on the inside surface by a durable non-allergenic foam pad 115. In FIG. 6, a top view of the knee brace assembly 20 is shown wherein the inside surface of the proximal cuff is provided with a VELCRO® hook patch 135 secured, e.g., glued, thereon that is arranged to be brought into engagement the plush exterior surface of the foam pad 115.
As shown in FIG. 7, the polycentric hinges 70 are also padded on the inside surface by a durable non-allergenic foam pad 120. The padded cuff and hinges are positioned to absorb anterior or frontal impacts, as well as lateral impacts to the outside of the leg and medial impacts to the inside of the leg.
Referring now to FIGS. 1, 6 and 7, the cuff strap 75 provides releasable securement of the proximal cuff 60 to the wearer's thigh 30. The cuff strap 75 may be formed of any suitable flexible material, e.g., nylon, and includes an elastic segment 77, VELCRO® loop segments 76 secured to the inner and outer surfaces thereof by any suitable means, e.g., sewing. The cuff strap 75 also includes VELCRO® hook segment 125 disposed at the free ends thereof. The free ends of the cuff strap 75 are slipped through and looped around elongated slots 130 located on opposite sides of the proximal cuff 60. Each free end of the cuff strap 75 is then folded back onto itself so that the hook segment 125 releasably engages the loop segment 76 thereby permitting the strap 75 to be tightened or loosened for comfort. The cuff strap 80 provides releasable securement of the distal cuff 65 to the wearer's leg below the knee 40 in a similar manner.
Referring now to FIGS. 1, 5 and 7, the medial and lateral depending portions 90 and 95 of the proximal cuff 60 each include a vertically oriented elongated slot 140. As best shown in FIG. 7, a strap guide assembly 145a is slidably mounted within the elongated slot 140 located on the lateral depending portion 95. Likewise, as best shown in FIG. 5, a strap guide assembly 145b is slidably mounted within the elongated slot 140 located on the medial depending portion 90 of the proximal cuff 60.
Referring now to FIGS. 3 and 4, the strap guide assembly 145a shown therein includes a ring portion 146 trapped within a bracket portion 148. The bracket portion 148 is disposed over the outside surface of the lateral depending portion 95 of the proximal cuff 60. The strap guide assembly 145a also includes a flange portion 149 disposed on the inside surface of the lateral depending portion 95 of the cuff. The bracket 148 and flange 149 portions of the strap guide assembly 145a are held together and slidably mounted to the slot 140 by means of a rivet assembly 147 that enables the strap guide assembly 145a to slidably move within the slot 140 between two extremes: a distal extreme, as shown in FIG. 1 and a proximal extreme, as shown in FIG. 7.
Referring again to FIG. 3, an elastic band 160, e.g., a rubber band, is anchored at one of its ends to the flange 149 by any suitable means, e.g., tying. At its opposite end, the elastic band 160 is anchored to the inside surface of the lateral depending portion 95 of the proximal cuff 60 by any suitable means, e.g., rivet 166. In this manner, the elastic band 160 serves as a means for normally biasing the strap guide assembly 145a to the proximal extreme within the vertically oriented slot 140 as shown in FIG. 7,
As best shown in FIG. 5, the strap guide assembly 145b is slidably mounted within the elongated slot 140 located on the medial depending portion 90 of the proximal cuff 60. The strap guide assembly 145b is similar in construction to the strap guide assembly 145a and includes a ring portion 165 trapped within a bracket portion 170 disposed over the outside surface of the medial depending portion 90 of the proximal cuff 60. The strap guide assembly 145b also includes a flange portion 175, the bracket and flange portions, 170 and 175, respectively, being held together and slidably mounted to the slot 140 by means of a rivet assembly 180 to enable the strap guide assembly 145b to slidably move between distal and proximal extremes. An elastic band 185, e.g., a rubber band, is anchored at one of its ends to the flange 175 by any suitable means, e.g., tying. At its opposite end, the elastic band 185 is anchored to the inside surface of the medial depending portion 90 of the proximal cuff 60 by any suitable means, e.g., rivet 190. In this manner, the elastic band 185 serves as a means to normally bias the strap guide assembly 145b to the proximal extreme within the vertically oriented slot 140 as shown in FIG. 5.
Referring now to FIGS. 1, 5 and 7, the prosthetic sleeve 55 is provided to assist in the attachment of the cross strap 50 and may be constructed of any suitable material, e.g., one-eighth inch thick neoprene having a brushed nylon outer surface and a smooth neoprene inner surface. The sleeve 55 is shown as being arranged to be wrapped around and secure to the wearer's leg portion just below the knee 40. An alternative sleeve, such as a full patella support sleeve which wraps around and secures to the wearer's thigh and calf, both above and below the wearer's knee could be utilized in substitution for the sleeve 55 in accordance with this invention. As best shown in FIG. 7, the sleeve 55 is provided with a laterally extending attachment strap 191 on which a VELCRO® hook segment is disposed. As best shown in FIG. 5, once the sleeve 55 is wrapped around the wearer's calf just below the knee 35, the hook segment on the attachment strap 191 releasably engages the plush outer surface of the sleeve 55 thereby permitting the sleeve 55 to be tightened or loosened for comfort.
Referring now to FIG. 7, the cross-strap 50 is formed of a non-elastic flexible web using any suitable material, e.g., nylon, and comprises an interior surface (best shown in FIGS. 2 and 7), an exterior surface (best shown in FIG. 2) and free ends to which VELCRO® hook patches 200 and 205 are secured. As best shown in FIGS. 2 and 7, VELCRO® loop segments 206 are secured to both the interior and exterior surfaces of the cross-strap 50 by any suitable means, e.g., sewing. Positioned on the interior surface of the cross-strap 50 approximately midway along the length thereof is a VELCRO® hook patch 195 arranged for releasable securement with the plush exterior surface of the sleeve 55 at a position on the sleeve 55 that lies over the wearer's tibia just below the wearer's knee 35. The positioning of the hook patch 195 on the outer surface of the sleeve 55 is best illustrated in FIG. 1 and by the dotted line 199 in FIG. 7. The cross-strap 50 is also provided with a pad 59 slidably mounted thereon to be positioned behind the wearer's knee when the cross-strap is secured to the wearer's leg in the manner described below.
Referring now to FIGS. 1 and 5, once the hook patch 195 cross strap 50 is releasably secured to the sleeve 55 in the manner described above, the proximal and distal cuffs 60 and 65 of the bracing component 45 are releasably secured to the wearer's thigh 30 and leg portion below the knee 40 by attachment with straps 75 and 80. As best shown in FIG. 2, a VELCRO® hook patch 209 is secured, e.g., glued, to the inside surface of the distal cuff 65 and is provided to engage with the plush exterior surface of the sleeve 55 thus providing an added means for securing the distal cuff 65 to the wearer's leg portion below the knee 40.
Thereafter, the free ends of the cross-strap 50 are crossed behind the wearer's knee 35 and slipped through and looped around the ring portions 146 and 165 of the pivotally mounted strap guide assemblies 145a and 145b. Each free end of the cross-strap 50 is then folded back onto itself so that the hook patches 200 and 205 releasably engage the loop segments 206 of the cross-strap 50 thereby permitting the cross-strap 50 to be tightened or loosened for comfort. The slidable pad 59 may be positioned behind the wearer's knee to suit the user's comfort. In accordance with this invention, when releasably securing the free ends of the cross-strap to the strap guide assemblies 145a and 145b, the wearer must maintain his or her knee in approximately thirty degrees of flexion. Moreover, the cross-strap must be applied to fit snugly around the wearer's knee but not so tightly as to be uncomfortable.
During use of the knee brace assembly 20, when the wearer's leg is fully flexed, the quadriceps muscle exerts only a relatively slight anterior displacement force on the tibia. This displacement force increases significantly as the wearer extends his or her leg closer and closer toward the fully extended position. It can be readily seen that when wearing the brace 20, as the wearer begins to extend his or her leg 25 towards full extension, the cross-strap 50 tightens geometrically around the wearer's knee 35 above and below the joint line and also applies posteriorly directed pressure to the anterior portion of the wearer's tibia just below the knee. The posteriorly directed pressure exerted against the tibia by the cross-strap 50 restrains anterior translation of the tibia.
At this juncture, it is important to point out that anterior tibial translation can result from a number of causes other than displacement forces created by the quadriceps muscle. For example, anterior tibial translation can result from force exerted against the tibia when the wearer is engaged in physical activity that involves sudden turning to the left or right, sudden stopping, jumping and running backwards. The posteriorly directed pressure exerted against the tibia by the cross-strap 50 will restrain anterior translation of the tibia during such physical activity.
At the same time, the cross-strap 50 applies a tensile force upon the strap guide assemblies 145a and 145b urging them to move from their normally biased proximal extreme to their distal extreme. As the strap guide assemblies move towards the distal extreme, the elastic bands 160, 185 will stretch and exert a counteractive tensile force upon the strap guide assemblies resistive to their distal movement. The movement of the strap guide assemblies enables the wearer to straighten his or her leg into full extension while applying increasing amounts of pressure to the wearer's tibia just below the knee.
Referring now to FIGS. 8 and 14, there is shown at 300 a second embodiment of the dynamic orthopedic knee brace assembly of the present invention. As best shown in FIG. 14, the knee brace assembly 300 shown therein comprises three basic parts: a bracing component 305, a cross-strap 310 and a sleeve 315. The knee brace assembly 300 functions to counteract anterior shifting of the tibia that can occur during physical activities that involve sudden turning to the right or left, sudden stopping, jumping or running backwards when the anterior cruciate ligament in the illustrated leg is missing or damaged.
As best shown in FIGS. 8 and 14, the bracing component 305 comprises a pair of elongated rigid thigh support members 320 and 325 extending along medial and lateral sides of the thigh, respectively, and a pair of elongated rigid lower leg support members 330 and 335 extending along the medial and lateral sides of the wearer's leg portion below the knee, respectively. The inner ends of the thigh and lower leg support pairs are pivotally interconnected by means of a pair of polycentric hinges 340. The thigh support members 320, 325, lower leg support members 330, 335 and polycentric hinges 340 are made of any suitable lightweight material, e.g., carbon fiber filament, thermosensitive carbon composite materials. Preferably, these components are fabricated from a material that is water resistant and non-corrosive to enable the wearer to use the knee brace assembly in a full range of activities including working, walking, and vigorous athletics. The polycentric hinges 340 are padded on the inside surface by a durable non-allergenic foam pad 345.
As best shown in FIGS. 8 and 14, the support members are releasably secured to the wearer's leg (not shown) above and below the knee by means of straps shown generally at 350, 352, 355, 360, 362, 365 and 367. Referring now to FIG. 9, a top view of the knee brace assembly 300 is shown therein illustrating the manner in which the straps 350 and 352 releasably secure the rigid thigh support members 320 and 325 to the wearer's thigh. The straps 350 and 352, shown therein, each include a VELCRO® hook segment 351 disposed at each end thereof. One end of the strap 350 is slipped through and looped around an elongated slot 375 located in the thigh support member 320 while the other end of the strap 350 is slipped through and looped around an elongated slot 380 located in the thigh support member 325. One end of the strap 352 is slipped through and looped around an elongated slot 385 located in the lateral thigh support member 320 while the other end of the strap 352 is slipped through and looped around an elongated slot 390 located in the medial thigh support member 325. Each end of the straps 350 and 352 is then folded back onto itself so that the hook segments 351 releasably engage VELCRO® loop segments secured, e.g., sewn, to the outer surface of the straps 350 and 352 thereby permitting the straps 350 and 352 to be tightened or loosened for comfort. Referring now to FIGS. 8 and 14, the strap 355 slips through and loops around elongated slots 381 and 386 and releasably engages to itself in the manner in which strap 350 and 352 releasably engage.
Referring now to FIG. 8, straps 355, 360, 362, 365 and 367 releasably secure the rigid lower leg support members 330 and 335 to the wearer's leg portion below the knee in a manner similar to that described above in connection with releasable attachment of the rigid thigh support members to the wearer's thigh using straps 350, 352 and 355.
Referring now to FIGS. 8 and 14, the rigid thigh support member 320 includes a vertically oriented elongated slot 395 in which a strap guide assembly 400 is slidably mounted. Similarly, the rigid thigh support member 325 includes a vertically oriented elongated slot 396 in which a strap guide assembly 405 is slidably mounted. The strap guide assemblies 400 and 405 each include a ring portion 410 trapped within a bracket portion 415. As best shown in FIGS. 10 and 11, the bracket portion 415 of each strap guide assembly 400 and 405 is disposed over the outside surface of the thigh support members 320 and 325. As best shown in FIGS. 8 and 13, each strap guide assembly 400 and 405 also includes a leaf spring 420 disposed on the inside surface of the thigh support members 320 and 325. As best shown in FIGS. 11 and 14, the bracket portion 415 and one end of the leaf spring portion 420 of the strap guide assemblies 400 and 405 are secured together and mounted on opposite sides of the elongated slots 395 and 396 by means of a rivet assembly 425 that enables the strap guide assemblies 400 and 405 to slidably move within the slots 395 and 396 between two extremes: a distal extreme, as shown in FIGS. 8 and 13, and a proximal extreme (not shown).
Referring now to FIGS. 13 and 14, as previously mentioned, one end of the leaf spring 420 is secured to the strap guide assemblies 400 and 405 by means of a rivet 425. At its other end, the leaf springs 420 is anchored to the inside surface of the rigid thigh support members 320 and 325 by means of a rivet assembly 430. In this manner, the leaf spring 420 serves as a means for normally biasing the strap guide assemblies 400 and 405 to the proximal extreme within the vertically oriented slots 395 and 396, respectively. At this juncture it is important to point out that rather than a leaf spring, alternative means could be employed for biasing the strap guide assemblies towards the proximal extreme, e.g., a coiled spring, an elastic band, a rubber band, etc.
Referring now to FIGS. 8 and 14, the prosthetic sleeve 315 is provided to assist in the attachment of the cross-strap 310 and may be constructed of any suitable material, e.g., one-eighth inch thick neoprene having a plush outer surface and a smooth neoprene inner surface. The sleeve 315 shown is a full patella support sleeve which wraps around and secures to the wearer's thigh and calf above and below the wearer's knee. As best shown in FIG. 14, the sleeve 315 is provided with a laterally extending attachment strap 316 on which a VELCRO® hook segment is disposed. The sleeve 315 also provides a patella opening 317 through which the knee can protrude when the sleeve 315 is worn. Once the sleeve 315 is wrapped around the wearer's leg, the attachment strap 316 releasably engages the plush outer surface of the sleeve 315 to be tightened or loosened for comfort.
The cross-strap 310 is formed of a non-elastic flexible web using any suitable material, e.g., nylon, and comprises free ends, an interior surface, shown in FIG. 14 and an exterior surface, hidden from view in FIG. 14. The interior surface comprises VELCRO® loop segments 440 secured thereto by any suitable means, e.g., sewing, and a centrally located VELCRO® hook patch 435 also secured thereto by any suitable means, e.g., sewing. The hook patch 435 is arranged for releasable securement with the plush exterior surface of the sleeve 315 just below the patella opening 317 of the sleeve 315. This position, as best illustrated by the dotted line 399 in FIG. 14, corresponds with the wearer's tibia. The exterior surface of the cross-strap 310 comprises VELCRO® hook patches 445 at the free ends thereof and a VELCRO® loop segment (not shown) extending therebetween. The cross-strap 310 is also provided with a pad 359 slidably mounted thereon to be positioned behind the wearer's knee when the cross-strap 310 is releasably secured to the wearer's leg.
Once the cross-strap 310 is releasably secured to the sleeve 315 at the location described above and illustrated in FIG. 14, i.e., just below the patella opening 317, the bracing component 305 is releasably secured to the wearer's thigh and leg portion below the knee using straps 350, 352, 355, 360, 362, 365 and 367. Thereafter, the free ends of the cross-strap 310 are crossed behind the wearer's knee and slipped through and looped around the ring portions 410 of the pivotally mounted strap guide assemblies 400 and 405. Each free end of the cross-strap 310 is then folded back onto itself so that the hook patches 445 releasably engage the loop segment secured thereby permitting the cross-strap 310 to be tightened or loosened for comfort.
During use of the knee brace assembly 300, when the wearer's leg is fully flexed, the quadriceps muscle exerts only a relatively slight anterior displacement force on the tibia. This displacement force increases significantly as the wearer extends his or her leg closer and closer toward the fully extended position. It can be readily seen that when wearing the brace 300, as the wearer begins to extend his or her leg towards full extension, the cross-strap 310 tightens geometrically around the wearer's knee above and below the joint line and also applies posteriorly directed pressure to the anterior portion of the wearer's tibia just below the knee. This posteriorly directed pressure exerted against the tibia by the cross-strap 310 restrains anterior translation of the tibia.
At this juncture, it is important to point out that anterior tibial translation can result from a number of causes other than displacement forces created by the quadriceps muscle. For example, anterior tibial translation can result from force exerted against the tibia when the wearer is engaged in physical activity that involves sudden turning to the left or right, sudden stopping, jumping and running backwards. The posteriorly directed pressure exerted against the tibia by the cross-strap 310 will restrain anterior translation of the tibia during such physical activity.
At the same time, the cross-strap 310 applies a tensile force upon the strap guide assemblies 400 and 405 urging them to move from their normally biased proximal extreme to their distal extreme. As best shown in FIG. 13, as the strap guide assemblies move towards the distal extreme, the leaf springs 420 will compress and exert a counteractive tensile force upon the strap guide assemblies resistive to their distal movement. The movement of the strap guide assemblies enables the wearer to straighten his or her leg into full extension while exerting additional counteractive force to prevent anterior translation of the tibia. | A knee brace assembly for various uses, e.g., restricting anterior tibial movement. The knee brace assembly includes a proximal cuff for engaging the wearer's leg above the knee and a distal cuff for engaging the wearer's leg below the knee. The proximal and distal cuffs are linked together by a hinge that permits pivotal movement of the proximal cuff relative to the distal cuff. The proximal cuff has lateral and medial portions each having a slot extending there along. A strap guiding assembly is slidably mounted within each of the slots. Each strap guiding assembly is arranged to slide between a proximal extreme when the wearer's leg is in flexion and a distal extreme as the wearer extends his or her leg. A biasing device biases each strap guiding assembly towards its proximal extreme. A cross-strap, having free ends and a length, is provided for engagement with the wearer's leg. The cross-strap attaches to the wearer's leg below the knee and wraps behind the knee in crisscross fashion. The free ends of the strap attach to the strap guiding assembly. The cross-strap is operative in response to extension of the wearer's leg to pull the strap guiding assembly from the proximal extreme towards the distal extreme thus creating a force counteractive to abnormal anterior movement of the tibia. | 0 |
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application claims the benefit of U.S. Provisional Application No. 60/791,342, filed Apr. 12, 2006.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The present invention relates generally to the field of plumbing devices and more particularly to an aerosol drain opener.
[0004] 2. Description of the Related Art
[0005] Many piping systems and similar plumbing configurations include drains of some type. Drains are known generally in the art as any type of pipe or similar conduit whereby a liquid may be drawn off. It is a generally common occurrence for these drains to become clogged over time, either partially or completely, in a manner that reduces their effectiveness. Not surprisingly, those skilled in the art have devised a number of approaches to alleviate this problem.
[0006] There are a variety of methods used to combat drainage problems. One solution includes the introduction of a force designed to push or pull clogged material out of a drain and nearby areas. This may be accomplished via manual plunging devices, or other means of introducing a pressurized force. Other methods include means for dissolving the clogging material, such as hot water, vinegar and sodium bicarbonate solutions, as well as various chemicals.
[0007] In general, the use of compressed gas for unclogging drains is known. For example, professional plumbers have used compressed gas canisters as a means for delivering a burst of compressed air against a clog, thereby dislodging it.
[0008] This concept was adapted for the home market by the introductions of aerosol clog removers. It has been believed that a narrowly directed stream of gas is preferred for creating a breach in a clog, thereby enabling a subsequently delivered stream of water or other solvents, to progressively dilate the clog until at least the majority of the clog has been dislodged.
[0009] For example, FIG. 1 depicts a prior art solution in an aerosol can 10 having a drain interface cap 2 and a drain mating member 4 . The mating member 4 is provided with an orifice 6 in fluid communication with a gas conduit 8 in the interface cap and with a conventional aerosol can valve (not illustrated). The valve is opened by compression between the interface cap and the aerosol can. In keeping with the prior art approach of delivering a narrowly focused jet of compressed gas, the diameter of the orifice is relatively narrow. As illustrated, the prior art diameter d is approximately 0.75 inch (roughly 2 cm).
[0010] Many sinks found in the home are provided with stopper mechanisms that are raised and lowered in a drain opening by use of a lever disposed in the drain itself. It is readily apparent that the prior art aerosol drain opening system shown in FIG. 1 cannot be used within such drains without at least partial disassembly of the stopper mechanism. Many homeowners do not want to perform this step due to difficulties in reinserting the stopper mechanism, and due to the tendency for such lever mechanisms to become coated with grime and other waste. Additionally, homeowners will often either fail to reinsert the stopper mechanism properly, or may even damage it beyond repair.
[0011] It is also apparent that the prior art approach is not suitable for use with larger drain openings, such as typically found with floor drains and toilets.
[0012] It has been found that the initial application of compressed gas only partially interrupts some clogs, thereby requiring the use of solvents, water, etc. to further clear the clog. Therefore, a more effective technique for enabling clog removal using aerosols is needed, in addition to one that is readily adapted for use with a variety of drain configurations.
BRIEF SUMMARY OF THE INVENTION
[0013] Therefore, it is an object of the present invention to provide a system for unclogging and otherwise clearing drains using aerosols to effectively clear clogs.
[0014] It is also an object of the present invention provide a system that uses aerosols for clearing drains and associated systems that is readily adaptable for use with a variety of drain configurations.
[0015] The present invention provides an improved system and method for using aerosols to effectively clear clogs in conduits such as drain pipes. As used in this application, the term “aerosol(s)” is used in its broadest sense to include any type of matter, solid, liquid or gas, typically contained within a releasably sealed container. Additionally, “aerosol” may mean: “of or containing a substance, such as a liquid or gas, under pressure for dispensing.” Also, when used in this application, the term “gas” refers to any type of gaseous substance, at any temperature, and may include substances that may or may not be in gaseous form at room temperature, and may or may not be inert, or active.
[0016] As opposed to the narrowly focused jet of compressed gas found in the prior art, the present invention recognizes and benefits from the superior drain clearing capability resulting from a broadly dispersed compressed gas wave. The term “wave” refers to a form or shape that a gas may take, wherein the gas is not a narrowly focused jet. When impacted by such a gas wave, the entire surface of a clog is contacted and dislocated. Water may then be used merely to translate the disrupted clog out of the pipe, rather than being used to continue the clog removal begun by the prior art.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
[0017] These and other features, aspects and advantages of the present invention will become better understood with reference to the following description, appended claims and accompanying drawings where:
[0018] FIG. 1 illustrates a prior art device.
[0019] FIG. 2 illustrates a perspective view of the present invention.
[0020] FIG. 3 illustrates a side perspective view of the present invention.
[0021] FIG. 4 illustrates an alternate perspective side view of the present invention.
[0022] FIG. 5 illustrates a perspective view of the drain interface cap of the present invention.
[0023] FIG. 6 illustrates a posterior perspective view of the drain interface cap of the present invention.
[0024] FIG. 7 illustrates a perspective view of the drain mating member of the present invention.
[0025] FIG. 8 illustrates a posterior perspective view of the drain mating member of the present invention.
[0026] FIG. 9 illustrates a perspective view of the adapter of the present invention.
[0027] FIG. 10 illustrates a posterior perspective view of the adapter of the present invention.
[0028] FIG. 11 illustrates a perspective view of the present invention including the adapter attached to the drain mating member of the present invention.
[0029] FIG. 12 illustrates a top perspective view of the present invention including the adapter attached to the drain mating member of the present invention.
[0030] FIG. 13 illustrates a side perspective view of the extension of the present invention.
[0031] FIG. 14 illustrates a perspective view of the extension of the present invention.
[0032] FIG. 15 illustrates a perspective view of the extension attached to the aerosol delivery device of the present invention.
[0033] FIG. 16A-16F illustrate the present invention employed in various drain configurations.
DETAILED DESCRIPTION OF THE INVENTION
[0034] As previously mentioned, FIG. 1 illustrates a well-known prior art device.
[0035] FIG. 2 represents a perspective view of a preferred embodiment of the present invention. In FIG. 2 , an aerosol delivery device 20 is provided with a drain interface cap 22 having a unique drain mating member 24 . The aerosol delivery device 20 may comprise an aerosol spray can or similar item. Also shown is orifice 26 formed in the mating member 24 , said orifice 26 having a diameter d′. Diameter d′ comprises a diameter that is approximately 1.75 inches (roughly 4.4 cm), which is substantially larger than that of the prior art. This configuration thus forms a gas dispersion region 30 within the mating member 24 and the drain interface 22 ; the dispersion region 30 being in fluid communication with gas conduit 28 , connected to an aerosol can valve.
[0036] FIGS. 3 and 4 provide alternate views of the aerosol delivery device 20 having the presently disclosed drain interface cap 22 with the drain mating member 24 installed therein.
[0037] A key feature of the present invention that distinguishes it from the prior art corresponds to the delivery of the gas used to unclog a drain. By relying on a narrow jet of gas the prior art teaches away from the unique features of the present invention. Rather than utilize a typical compressed gas (ex. compressed air, CO2, nitrogen), the present invention incorporates a substantially uniform wave of high pressure gas, derived from the use of a liquefied propellant, preferably tetrafluoroethane. Tetrafluoroethane maintains a constant pressure (whether the can is full or partially full), unlike other compressed gases, and when emitted is extremely cold. Further, it is non-flammable and contains no CFCs, thus causing no harm to sound pipes or the environment. In addition to enabling a substantially uniform high pressure wave of gas to be applied across the surface of a clog, a cutting agent such as dimethylketone is preferably employed for delivery with the gas. Tetrafluoroethane is used to instantly freeze the clog upon impact, rendering the clog more prone to fracturing and being displaced as larger pieces, resulting in a more immediate opening of the pipe or drain. Of course, the temperature of the clog rises after displacement, after which the displaced pieces of the clog are prone to dispersal. Dimethylketone is a solvent which aids in the removal of residual portions of the clog and the dispersal of the dislocated pieces.
[0038] Preferably a fragrance is also provided for application with the gas. Odors associated with rotting or degrading material comprising or beyond the clog are thus masked.
[0039] In a further embodiment, another fluid is included in the contents of the aerosol can which acts to coat the interior of the drain pipe with a smooth, non-toxic coating. Such a material assists in retarding the buildup of clogging materials and facilitates future clog dislodgement. In one embodiment this material is a silicone-like product.
[0040] FIGS. 5 and 6 illustrate the drain interface cap 22 of the present invention. The drain interface cap 22 is preferably formed of molded plastic or copolymer polypropylene, which is resistant to the effects of the propelled solvent. The material is also sufficiently pliable to resist cracking with rough use, is light-weight, and is non-porous so as to prevent the absorption of odors and/or other materials, such as bacteria, fecal matter, etc., associated with clogged sinks or toilets.
[0041] FIGS. 7 and 8 illustrate the drain mating member 24 which is normally disposed within the drain interface cap 22 . The drain mating member 24 is preferably formed of a resilient material such as rubber or clear gloss flexible vinyl, with a density selected to minimize the risk of scratching or otherwise marring a surface adjacent a treated drain, or to the drain itself. The pliable nature of the material also enables the drain mating member 24 to conform to a degree to irregular surface features to provide a tighter seal for maximum effectiveness and to avoid the risk of slipping out of position during delivery. The interior diameter of drain interface cap 22 and drain mating member 24 are selected to form a gas dispersion region 30 (See FIGS. 2 and 3 ) which enables the compressed gas to disperse, and for pressure to equalize prior to impacting the clog.
[0042] Another benefit associated with the configuration of the drain interface cap 22 and drain mating member 24 is that they can be used with drains having pop-up type stopper mechanisms without the need for removing the mechanism. For example, the selected gas dispersion region 30 diameter will accommodate most commonly encountered bathroom and bathtub drain stoppers.
[0043] FIGS. 9 through 12 depict an adapter 34 that is configured for use with the present invention. The adapter 34 includes an adapter mating member 42 having an outer dimension d″ that is substantially identical to the inner diameter d′ of the drain mating member 24 . An inner sealing ring 36 and an outer sealing ring 38 provide lower mating surfaces that are substantially coplanar in a preferred embodiment. For drains of a diameter substantially the same as that of the inner sealing ring 36 , compressed gas is delivered in substantially the same manner as with the drain mating member 24 alone. This is due to the fact that the space within the inner ring serves as an extension of the gas dispersion region 30 .
[0044] For drains that have a diameter greater than that of the inner sealing ring 36 but less than that of outer sealing ring 38 , the outer sealing ring 38 serves to enable the application of the compressed gas to the clog with only a small decrease in total pressure due to the region between the inner and outer sealing rings 36 and 38 being in fluid communication with the gas flow path. The shallow angle of the outer surface 40 of adapter 34 with respect to a horizontal plane helps minimize this pressure decrease in a preferred embodiment.
[0045] In addition to the configurations illustrated in FIGS. 11 and 12 , the adapter 34 can also be configured to receive the drain interface cap 22 , with or without the drain mating member 24 , inserted within the inner sealing ring 36 . In this manner, the adapter mating member 42 can be inserted into an orifice such as within a toilet bowl, the outer surface 40 of the adapter acting as a sealing interface to the bowl itself.
[0046] The adapter 34 is preferably provided of clear gloss flexible vinyl, with a specifically selected density that allows for superior pliability and conformance in a preferred embodiment. The pliability of this material is preferred for its enhanced conforming capabilities, while still being non-porous and thus resistant to odor, liquid, bacteria and fecal matter absorption. Plurality of trusses 44 are preferably employed intermediate the inner sealing ring 36 and the underside of the adapter outer surface 40 to resist vertical deformation of the outer surface 40 .
[0047] FIGS. 13 through 15 illustrate an additional element, extension 50 , of the present invention in an alternate embodiment. Extension 50 is useful in a variety of situations; including clogged toilets or clogged drains that are not readily accessible by hand, or that are under an accumulation of water or other substance. The extension 50 preferably includes a handle 52 at the proximal end of extension 50 , which may include finger indentations or similar additions including non-slip material to form an improved grip. At the distal end, a receptacle 54 is formed as a substantially open cylinder. The diameter of the receptacle 54 is preferably slightly greater than that of the aerosol delivery device 20 . Preferably, the inner surface of the receptacle 54 is provided with a plurality of ribs 56 , preferably three or more, that may extend slightly into the receptacle 54 , and which may engage the outer surface of aerosol delivery device 20 once inserted into the receptacle 54 . The plurality of ribs 56 act to prevent the aerosol delivery device 20 from becoming disengaged from extension 50 once inverted. Additional ribs may be formed on the bottom interior surface of receptacle 54 to prevent an aerosol delivery device 20 comprising a concave bottom from becoming vacuum adhered to the bottom interior surface of receptacle 54 . An air release in the form of an air hole may be provided in the bottom surface of the receptacle 54 in an alternate embodiment to enable air to enter and exit the receptacle 54 as the aerosol delivery device 20 is remove or inserted.
[0048] Preferably, the extension 50 is formed of a semi-rigid material such as molded plastic or copolymer polypropylene. The selected material is chosen to resist odor and liquid retention. Structural ribs may be provided to increase the rigidity of the extension 50 without significantly increasing its weight or size.
[0049] While the presently disclosed system benefits from its flexibility in terms of adapting to various drain configurations, certain specific examples of use are illustrated in FIGS. 16A through 16F as examples, not as limitation. For example, the aerosol delivery device 20 with the drain interface cap 22 and the drain mating member 24 may be sufficient for use with a single sink, double sink, garbage disposal, and bathtub, as seen in FIGS. 16A through 16D . For drains with an overflow drain or second interconnected drain, it may be necessary to apply a wet washcloth or drain plug to the other drain to maximize the pressure applied to the clog.
[0050] To operate in conjunction with a larger drain opening, such as that of a toilet, and as illustrated in FIG. 16E , the adapter 34 may be installed on the drain interface cap 22 in an inverted position with the adapter mating member 42 projecting into the toilet drain. It will be noted that this illustration depicts the optional use of the extension 50 . Finally, for larger diameter drains such as floor drains, the adapter 34 is employed with the inner sealing rings 36 and outer sealing ring 38 facing the drain. Water may also be used to improve the seal between the adapter 34 and the floor surrounding the drain.
[0051] Together, the previously disclosed elements provide an adaptable system for effectively removing clogs from a variety of drains and/or other openings.
[0052] Although the present invention has been described with reference to particular embodiments, it will be apparent to those skilled in the art that variations and modifications can be substituted therefore without departing from the principles and spirit of the invention. | The present invention comprises a system and method for unclogging drains, piping systems and related items. The system employs an aerosol delivery of a broadly dispersed compressed gas wave. Preferably, the gas comprises the liquefied propellant Tetrafluoroethane that freezes the clog, allowing for more efficient break up of the clog. Solvents, fluid coatings and fragrance may also be employed to further improve the efficiency of the system. Additionally, an extension and/or adapter may also be employed, thereby providing a single system capable of unclogging drains and associated systems of almost any size or type. | 4 |
BACKGROUND OF THE INVENTION
[0001] Field Of the Invention
[0002] This invention relates generally to electronic appliances that have detachable peripheral devices. Specifically, the invention pertains to a system and method for enabling an electronic appliance to verify the authenticity of a detachable peripheral device before that peripheral device is used, and thereby avoid potential problems that may occur when attaching a peripheral device that is not authorized to operate with a particular electronic appliance.
[0003] Description of the Prior Art
[0004] Numerous consumer and commercial electronic appliances have removable or add-on peripheral components. The peripheral components provide value, flexibility, and/or convenience to the user. For example, many peripheral devices are consumable and are intended to be replaced, such as ink or toner cartridges used in printers, where the ink and toner cartridges are the removable peripheral devices and the printer is the electronic appliance.
[0005] Other examples of electronic appliance and peripheral device combinations include but should not be considered as limited to devices with a rechargeable battery such as drills, laptop computers, mobile telephones, cameras, music playing devices, touch panels and replacement parts in white goods.
[0006] It should be understood that there are many other electronic appliances and many other removable peripheral devices that may fall within the scope of the present invention. Accordingly, it should be understood that the list above are only examples and the invention is not limited by the list.
[0007] To maintain high quality standards and to protect profits, manufactures want to eliminate the use of counterfeit or unauthorized peripheral devices. Furthermore, consumers don't want to buy low quality counterfeits that may damage the electronic appliance. Another problem that may occur is that peripheral devices may be illegally produced at the same factory as the original products, but the factory may sell the illegal peripheral devices through other channels without authorization.
[0008] One method that is used in the prior art to discourage the use of counterfeit peripheral devices may be to include an authentication integrated circuit (IC) chip in the peripheral devices. The electronic appliance must then authenticate the peripheral device by scanning for the presence of the authentication IC chip before allowing the peripheral device to function. Unfortunately, these authentication schemes may add significant cost to the electronic appliance and/or to the peripheral devices.
BRIEF SUMMARY OF THE INVENTION
[0009] In a first embodiment, the present invention is a system and method for enabling an electronic appliance to verify the authenticity of a peripheral device before that peripheral device is attached to the electronic appliance. The peripheral device may be a new device that is attached in order to provide additional functionality to the electronic appliance such as a keyboard, mouse, touchpad, memory storage device, microphone, speaker, camera or web-camera. The peripheral device may also be a replaceable component such as a battery or toner cartridge. These examples should not be considered to be limiting but only as examples of possible peripheral devices.
[0010] Before the peripheral device is activated, for example, by using it or providing power to it, the peripheral device may be tested or verified. The testing or verification process may be accomplished by any convenient means. For example, the peripheral device might be tested by measuring a controlled impedance of a common wire, wherein the electronic appliance may change or modulate the impedance of the wire before or during each measurement of the peripheral device. If the peripheral device's reported impedance measurement matches the expected response of the electronic appliance, then the invention may allow the peripheral device and the electronic appliance to function together.
[0011] In another aspect of the invention, if the peripheral device's reported response didn't match the expected response, then the electronic appliance may take an action that prevents the peripheral device from functioning. For example, the electronic appliance may disable the peripheral device, it may display a notice of incompatibility, it may allow limited functionality, or it may allow full functionality for a limited amount of time. These examples should not be considered as limiting of all the possible responses by the electronic appliance.
[0012] These and other objects, features, advantages and alternative aspects of the present invention will become apparent to those skilled in the art from a consideration of the following detailed description taken in combination with the accompanying drawings.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
[0013] FIG. 1 is a block diagram of a system that may implement the embodiments of the invention.
[0014] FIG. 2 is a block diagram of operation of a touch sensor that is found in the prior art, and which is adaptable for use in the present invention.
DETAILED DESCRIPTION OF THE INVENTION
[0015] Reference will now be made to the drawings in which the various elements of the present invention will be given numerical designations and in which the invention will be discussed so as to enable one skilled in the art to make and use the invention. It is to be understood that the following description is only exemplary of the principles of the present invention, and should not be viewed as narrowing the claims which follow.
[0016] FIG. 1 is a block diagram showing a first embodiment of the invention. In this first embodiment there is an electronic appliance that may also be referred to interchangeably as a host device 30 . A peripheral device 32 is also shown that may be connected externally or internally to the host device 30 . Thus, the peripheral device 32 may be an external device that is coupled by an electrical connector such as a USB cable or a lightning cable to the host device 30 . Alternatively, the peripheral device 32 may be an internal device such us a battery or a toner cartridge. None of the examples of the peripheral devices 12 should be considered to be limiting regarding the nature or function of the peripheral devices.
[0017] A first embodiment of an authentication system may be comprised of a circuit within the host device 30 and the peripheral device 32 . The authentication system may be any system that enables the host device 30 to authenticate the peripheral device 32 . The authentication system may be part of any connection between the host device 30 and the peripheral device 32 . The authentication system may be capable of interrupting or preventing communication between the host device 30 and the peripheral device 32 .
[0018] One example of a specific authentication system of the first embodiment is shown in FIG. 1 . FIG. 1 shows that the host device 30 may include a host custom integrated circuit 34 that toggles a controlled impedance wire 36 (CIW) through a variable capacitor network within the host custom integrated circuit, wherein the toggling is synchronous with a peripheral custom integrated circuit 38 that may be disposed in the peripheral device 32 that may perform an impedance measurement. The host device and the peripheral device 32 may communicate through a communication bus 40 . The communication bus 40 may also include power from the host device 30 to the peripheral device 32 .
[0019] The CIW 36 may also be a communication link between the host device 30 and the peripheral device 32 .
[0020] The impedance of the CIW 36 may typically be caused to change by very small amounts by the host device 30 . Such small impedance changes may only be detectable by the host custom integrated circuit 34 and the peripheral custom integrated circuit 38 , or by very expensive counterfeit measurement systems. The impedance with respect to ground may also be measured and reported. The host custom integrated circuit 34 and the peripheral custom integrated circuit 38 may be inexpensive items when the authentication system uses a touch sensor circuit from Cirque Corporation.
[0021] In a typical scenario of the first embodiment, the peripheral device 32 may be attached to the host device 30 at some connector, wherein the connector is coupled to the communication bus 40 . In this first embodiment, the host device 30 may test the authenticity of the peripheral device 32 before the function or functions of the peripheral device is used by the host device.
[0022] The authentication system used by the host device 30 and the peripheral device 32 may then perform the operations necessary for an impedance measurement to be made using the host custom integrated circuit 34 and the peripheral custom integrated circuit 38 that enables the host device to authenticate the peripheral device.
[0023] In another embodiment, the two-way communication link of the communication bus 40 may be on the same wire as power to thereby minimize the number of conductors between the host device 30 and the peripheral device 32 .
[0024] In another embodiment, the CIW 36 may also function as the power wire where the power, communication, and impedance measurements are all on the same wire and may be all simultaneous functions, sequential functions, or combinations of sequential and simultaneous functions but at different times.
[0025] In another embodiment, the peripheral impedance measuring circuit 18 may regulate the voltage on the CIW 36 such that the host device 30 may detect that the peripheral device 32 is using a regulated analog front end. However, such front ends may be more difficult to build.
[0026] In another embodiment, the host device 30 and peripheral device 32 may each perform multiple impedance measurements where one or both of the host device 30 and the peripheral device 32 change the impedance of the CIW 36 .
[0027] In another embodiment, the host device 30 may perform impedance measurements on the CIW 36 with expectations of certain impedances when the peripheral device 32 is disabled versus when it's enabled and configured with certain output impedances. This embodiment may also be capable of detecting snooping devices that may be connected to the CIW 36 .
[0028] In another embodiment, the host or peripheral impedance measurement circuits 14 , 18 may dynamically change the voltage in a random pattern which the host device 30 may recognize, while a counterfeit circuit would have difficulty duplicating the same precise voltage changes.
[0029] In another embodiment, there are two CIWs 16 that connect the peripheral device 32 to the host device 30 , where one of the devices 10 , 12 initiates a measurement (the “initiator”) where one CIW 36 has a transmit signal disposed on it and the other CIW 36 has a receive signal on it. The receiving device (the “receiver”) changes the impedance between the transmit CIW and the receive CIW and between ground. The initiator sends the answer to the receiver where the receiver compares the answer to what it expected based on how it changed the impedance.
[0030] In another embodiment, the peripheral device 32 may include an impedance integrated circuit or the peripheral impedance measurement circuits 18 may include a number of resistors, capacitors, inductors and diodes connected in such a way that it would be very difficult to reproduce. The host device 30 would then perform one or more impedance measurements on the impedance integrated circuit that is connected with the CIW 36 .
[0031] Typically the impedance integrated circuit would not be powered and may only have two ports. The host device 30 may perform any number of random type measurements on a particular part of the impedance integrated circuit. For example, the DC voltage may be raised to put a diode in the impedance integrated circuit in a different operating region. Another example may be to change the frequency where a certain part of the impedance integrated circuit would have a different impedance.
[0032] The embodiments of the invention may include the host or peripheral impedance measurement circuits 14 , 18 having a very sensitive impedance measurement capability and the amount of impedance changes would be very small, on the order of a few femtofarads.
[0033] A circuit that may be adapted for use in the embodiments of the invention may be a capacitance sensing circuit used in touch sensors. The host custom integrated circuit 34 and the peripheral custom integrated circuit 38 that enables the host device to authenticate the peripheral device may use capacitance or voltage as a system of authentication. It is useful to examine the underlying technology of the touch sensors to better understand how any capacitance sensitive touch sensor may be used in the present invention.
[0034] The CIRQUE® Corporation touch sensor is a mutual capacitance-sensing device and an example is illustrated as a block diagram in FIG. 2 . In this touchpad 10 , a grid of X ( 12 ) and Y ( 14 ) electrodes and a sense electrode 16 is used to define the touch-sensitive area 18 of the touchpad. Typically, the touchpad 10 is a rectangular grid of approximately 16 by 12 electrodes, or 8 by 6 electrodes when there are space constraints. Interlaced with these X ( 12 ) and Y ( 14 ) (or row and column) electrodes is a single sense electrode 16 . All position measurements are made through the sense electrode 16 .
[0035] The CIRQUE® Corporation touchpad 10 measures an imbalance in electrical charge on the sense line 16 . When no pointing object is on or in proximity to the touchpad 10 , the touchpad circuitry 20 is in a balanced state, and there is no charge imbalance on the sense line 16 . When a pointing object creates imbalance because of capacitive coupling when the object approaches or touches a touch surface (the sensing area 18 of the touchpad 10 ), a change in capacitance occurs on the electrodes 12 , 14 . What is measured is the change in capacitance, but not the absolute capacitance value on the electrodes 12 , 14 . The touchpad 10 determines the change in capacitance by measuring the amount of charge that must be injected onto the sense line 16 to reestablish or regain balance of charge on the sense line.
[0036] The system above is utilized to determine the position of a finger on or in proximity to a touchpad 10 as follows. This example describes row electrodes 12 , and is repeated in the same manner for the column electrodes 14 . The values obtained from the row and column electrode measurements determine an intersection which is the centroid of the pointing object on or in proximity to the touchpad 10 .
[0037] In the first step, a first set of row electrodes 12 are driven with a first signal from P, N generator 22 , and a different but adjacent second set of row electrodes are driven with a second signal from the P, N generator. The touchpad circuitry 20 obtains a value from the sense line 16 using a mutual capacitance measuring device 26 that indicates which row electrode is closest to the pointing object. However, the touchpad circuitry 20 under the control of some microcontroller 28 cannot yet determine on which side of the row electrode the pointing object is located, nor can the touchpad circuitry 20 determine just how far the pointing object is located away from the electrode. Thus, the system shifts by one electrode the group of electrodes 12 to be driven. In other words, the electrode on one side of the group is added, while the electrode on the opposite side of the group is no longer driven. The new group is then driven by the P, N generator 22 and a second measurement of the sense line 16 is taken.
[0038] From these two measurements, it is possible to determine on which side of the row electrode the pointing object is located, and how far away. Using an equation that compares the magnitude of the two signals measured then performs pointing object position determination.
[0039] The sensitivity or resolution of the CIRQUE® Corporation touch sensor may be used to detect a signal between the host device 30 and the peripheral device 32 . For example, the host device 30 may include a touch sensor circuit that is able to detect a precise capacitance or voltage generated by the peripheral device 32 .
[0040] Although only a few example embodiments have been described in detail above, those skilled in the art will readily appreciate that many modifications are possible in the example embodiments without materially departing from this invention. Accordingly, all such modifications are intended to be included within the scope of this disclosure as defined in the following claims. It is the express intention of the applicant not to invoke 35 U.S.C. §112, paragraph 6 for any limitations of any of the claims herein, except for those in which the claim expressly uses the words ‘means for’ together with an associated function. | A system and method for enabling an electronic appliance to verify the authenticity of a detachable peripheral device before that peripheral device is used by measuring a controlled impedance of a common wire and returning a proportional value, wherein the host may change or modulate the impedance of the wire before or during each measurement that the peripheral device makes, and if the peripheral device's reported answer matches the expected answer of the host, then the host device may allow the peripheral device to function properly. | 8 |
BACKGROUND OF THE INVENTION
This invention is concerned with window units of the airtight double-hung sash type, such as are being currently installed in homes and particularly in apartment buildings. More particularly, it is concerned with the provision of a vented heading for such units.
The conventional airtight window unit has a pair of sash vertically slidable relative to each other to open and closed positions in side tracks of an encasing frame. When closed, the sashes are airtight to the extent of being sealed against entry of outside fresh air and against escape of inside stale air. Further, the sashes are double glazed. This characteristic, together with the airtight feature serves to create an undesirable aerobic condition within the related apartment. It tends to produce, during any period that the windows remain closed, harmful effects not only upon the interior structure of the apartment but also upon its occupants.
Humidity, condensation and dampness develop in apartments having such window units. This is due to a lack of ventilation through the airtight unit when the sashes remain in a closed condition. Resulting mold growth destroys walls, floors and furniture in the apartment. The humidity and condensation, together with periods of excessive dryness destroys walls, paint and wall paper, warps woodwork and doors, and subjects the occupants of the apartment to sore throats, colds and other discomforts.
Accordingly, a general object of the present invention is to provide the conventional airtight window unit with an improvement which will serve to avoid the harmful effects mentioned and will not materially diminish the general purpose for which such airtight window units are intended.
A more particular object of the invention is to provide a vented heading for an airtight double-hung sash window unit which will provide a desirable exchange of stale room air with fresh outside air.
The invention, together with its various advantages will become increasingly apparent as this specification unfolds in greater detail and as it is read in conjunction with the accompanying drawing, wherein a preferred and specific embodiment of the invention is illustrated.
Briefly, in accordance with the invention an airtight window unit of the double-hung sash type is provided with a heading having vent holes fitted with screened vent plugs. The vent plugs allow a desirable degree of exchange of stale room air with outside fresh air through the heading. Before the outside air flows from the heading to the related room, it is acted upon by a baffle member so that it flows gently into the room without creating undesirable drafts. The baffle member, which is a part of the heading, also serves as decorative interior trim at the room side of the window unit. The screened vent plugs may be varied in number so as to provide a controlled and desirable degree of ventillation to the room.
BRIEF DESCRIPTION OF THE DRAWING
In the drawing:
FIG. 1 is an elevational view of the upper front portion of an airtight double-hung sash window unit embodying the invention, the unit being shown as seated in a window opening of an exterior wall of an apartment;
FIG. 2 is an elevational view of the upper rear portion of the window unit at the room side of the wall;
FIG. 3 is a section on line 3--3 of FIG. 2;
FIG. 4 is an enlarged detail of the baffle member, showing its mounted relation to the heading;
FIG. 5 is an enlarged plan view of the head of one of the vent plugs; and
FIG. 6 is a section on line 6--6 of FIG. 5.
DETAILED DESCRIPTION OF THE INVENTION
Reference is now directed to the accompanying drawing, wherein there is shown a window opening 1 in an exterior wall 3 of an apartment. The opening is of conventional rectangular form. It has a shoulder 2, here in the conventional form of a Z-bar, extending into the opening from its walls. A window unit 4 is adapted to be entered in the opening and seated against the shoulder. The window unit is an airtight double-hung sash type.
The window unit includes an outer casing or frame 5 having top and side walls 6, 7 and a bottom wall or sill, not shown. The lower portion of the unit is conventional and not shown since the upper portion of the unit is adequate for a clear understanding of the invention.
A pair of complementary double-hung sashes 8, 9 is encased by the frame. These are slidable vertically relative to each other in conventional tracks in the side walls 7. The sashes are shown as being double glazed, as at 11. When closed, the sashes have an airtight relation to each other and to the frame. A short shoulder 12 depending along the rear end of the top wall 6 of the frame serves as a stop for the rear sash member 9. The shoulder 12 also extends down the side walls 7.
The upper end of the frame is defined by a heading 14. This includes the top wall 6 of the frame. A head panel 15 defines a front end to the heading. The head panel is co-extensive with and extends vertically upward from the forward end of the top wall. Mounted to an upwardly extending shoulder 16 of the rear end of the top wall is a baffle member 17 which defines a rear or back to the heading.
The head panel 15 has a plurality of vent holes 18 opening into a space 19 defined between the head panel and the baffle member. Plugged into each vent hole is a vent plug 21 having an axially extending screened hole 22 through its head 23. The plug is formed preferably of metal or plastic material. A group of flexible fingers 24 extend rearwardly from the back of the plug, and a screen 25 is seated at the back of the head over the hole, as appears in FIG. 6. The plug is adapted to be seated in a vent hole 18 by first flexing its fingers and pushing them through the hole until the head of the plug abuts the face of the panel 15. As the fingers project from the rear of the hole, they expand to secure the position of the plug.
The baffle member 17 is removably mounted to a supporting clip 26 that is fastened to the upper shoulder 16 of the top wall of the frame. The clip is of C-form. Its back wall is fixed by a fastener 26a to the shoulder. Upper and lower rearwardly extending arms 27, 28 of the clip terminate, respectively, in coupling elements 29, 30. The baffle member is of L-form. It has a vertical elongated panel 31 which extends in part above the top wall 6 and shoulder 16, and in part depends below the top wall and the stop shoulder 12. A relatively narrow arm 32 extends forwardly from the lower end of the panel. Along the upper end of the baffle panel 31 is a coupling element in the form of a hook 33 having a snapped-in engagement with a complementary notch defining the coupling element 29 of the C-clip; and extending off and along the mid-area of the baffle panel is a coupling element in the form of a notch 34 which complements and has a snapped-in engagement with a hook defining the coupling element 30 of the C-clip. The lower arm 32 of the baffle member is spaced, as at 35, below and clear of the stop shoulder 12.
The window unit 4 is seated in the wall opening 1 against the shoulder 2. In this respect, the upper end and sides of the head panel 15 are seated against complementary portions of the shoulder 2. Side panels 10 of the frame 5 are seated against side portions of the shoulder 2. A bottom panel, not shown, of the frame is seated against a lower section of shoulder 2.
The window unit is held seated against the shoulder 2 by means of the clip 26, the upper arm 27 of which is fixed by a fastener to a ceiling wall 38 of the wall opening. A vertical slot 39 in the back wall of the clip enables the clip to be adjustably moved up or down relative to its fastener 26a so as to abut the upper arm of the clip against the ceiling wall 38. The fastener 26a is tightened after the adjustment is made. Other clips 41, secured to the shoulder stop 12 and to side walls of opening 1, further secure the seated condition of the window unit. Clips 41 have a snapped-in engagement with side trim at the room side of the window unit.
The rear of the baffle panel 31 faces the room-side of the seated window unit. In this respect the baffle panel serves not only to baffle incoming air to the room, but also serves as trim for the upper end of the window unit, as in FIG. 2.
It should now be apparent that, by means of the heading 14 provided for the window unit, a desirable degree of ventilation to the room side of the window unit is possible to counteract the undesirable aspects of the airtight window unit. In this respect, fresh air entering through the screened vent plugs 21 flows through the space 19 in the heading toward the baffle panel 31. It is baffled or diverted by the latter downward against and over its lower arm 32 and through the space 35 below the stop shoulder 12 to the interior of the related room. The baffled air flows gently from the space 35 to the room without creating undesirable drafts. Foul air from the room is exchanged through the vented heading with fresh air.
Here, it has been determined that three vent plugs 21 having a screened hole of small diameter, preferably about three-fourths of an inch, provide a desirable degree of air flow through the heading.
It is apparent that the degree of ventilation or air flow through the heading may be controlled by using all of the vent plugs, or by sealing one or more of the vent holes 18 with replacement plugs having a solid head.
The screen 25 in the vent plug serves to block out entry of dust particles and insects through the heading. The head 23 of the vent plug is preferably convexed. This form, together with the relatively small size of the head serves to avert entry of rain through the plug.
While I have described what I consider to be a desirable embodiment of my invention, it is my intent, however to claim all such forms of the invention as may be reasonably construed to be within the spirit of the invention and the scope of the appended claims. | A vented heading for the outer frame of an airtight double-hung sash window unit adapted to be seated in an opening of an exterior wall of an apartment. Vent holes in a head panel allow fresh air flow into the heading; and a baffle member at the back of the heading serves to direct the airflow downwardly at the rear of the unit into the apartment. Stale air from the apartment is enabled to move past the baffle member and escape through the heading and vent holes to the outside. | 4 |
GOVERNMENT CONTRACT
This invention was conceived or first reduced to practice in the course of, or under Contract No. N00024-86-C-4030 between Westinghouse Electric Corporation and the United States Government, represented by the Department of the Navy.
CROSS REFERENCE TO RELATED APPLICATIONS
This application is related to co-pending applications entitled A Dogging Mechanism, Ser. No. 07/669541 and A Water Tight Door, Ser. No. 07/669258 both filed on the same day as this application.
BACKGROUND OF THE INVENTION
The invention relates to a gasket and more particularly to a gasket that is confined in a partial enclosure and maintains its seal when either side is subjected to higher pressure.
Seals on many of the hatches, scuttles and bulkhead doors on ships use flat gaskets and knife edges to effectuate a seal and require very high sealing forces to produce a seal. These seals are very sensitive to warpage and knife edge damage, which causes them to leak.
SUMMARY OF THE INVENTION
Among the objects of the invention may be noted the provision of a seal which requires small initial sealing force, does not require fine finished machined surfaces or knife edges and will accommodate a considerable amount of warpage.
In general, a double directional gasket for forming a fluid tight seal between a first member having a groove about its periphery and a second member having an L shaped portion about its periphery, when made in accordance with this invention, comprises a gasket having two extensive margins, one of the margins having a thick portion adjacent thereto, which is configured to form a seal and be captured within the groove. The other margin is tapered to a small radius and disposed to seat adjacent the corner of the L shaped portion. A strip like portion extends at a angle from the thick portion to the tapered portion and toward the corner of said L shaped portion, when the seal is being formed. The grooved portion has an extension, which cooperates with the L shaped portion to form a peripheral partial enclosure in which the cross section of the strip portion of the gasket forms a general S shape, to produce a fluid tight seal irrespective of the side of the gasket subjected to high pressure.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention as set forth in the claims will become more apparent by reading the following detailed description in conjunction with the accompanying drawings, wherein like reference numerals refer to like parts throughout the drawings and in which:
FIG. 1 is a plan view of a gasket made in accordance with this invention;
FIG. 2 is an enlarged sectional view of the gasket taken on line 2--2 of FIG. 1;
FIG. 3 is an enlarged sectional view of the gasket taken on line 3--3 of FIG. 1; and
FIG. 4 is an enlarged sectional view of the gasket in a partial enclosure forming a seal.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring now to the drawings in detail and in particular to FIG. 4, there is shown a double directional gasket 1 used to form a fluid seal between a first structure 3 having a groove 5 disposed adjacent its periphery, the groove having an extended wall 6, and a second structure 7 having an L shaped portion 9 disposed adjacent its periphery, which cooperates with the groove 5 and extend wall portion 6 to form a partial enclosure 11 having a generally rectangular cross section.
The gasket 1, as shown in FIGS. 1, 2 and 3 comprises a continuous band having a pair of extensive margins. One of the margins has a thick portion 13 with a generally rectangular cross section adjacent thereto. The other margin has a cross section shaped generally like an arrowhead, this arrowhead shaped portion 15 has a pair of converging generally flat surfaces 16 and 17, which blend into an arcuate portion having a relatively small radius forming a tip 18. A strip portion 19 is disposed to extend between the thick portion 13 and arrowhead shaped portion 15 at an included angle of about 130° from the top surface of the thick portion 19 in the straight portions. Arcuate portions 20 of the gasket 1 generally have an included angle of 135°. These angles cooperate with the disposition of the enclosure portions to provide the proper contact between the tip 18 and a leg of the L shaped portion 9. Large hatches on commercial ships, which are opened and closed using a crane rather than being hinged, may require different angles and larger L shaped portions.
The thick portion 13 has an intermediate portion 21, which is not as thick as the portion adjacent the margin. The intermediate portion 21 is disposed adjacent the strip portion 19. The thick portion 13 also has a wedge shaped portion 23 forming the corner adjacent the intermediate portion 21. The thick portion 13 is slightly smaller than the opening in the groove portion 5 allowing the thick portion 13 to be inserted into the groove 5 when a reasonable insertion force is applied up to the point where the wedge shaped corner 23 contacts the groove 5, at which time additional insertion force must be applied to deform the wedge shaped corner 23. The additional force deforms the wedge shaped corner 23 until the thick portion 13 is seated in the groove 5. This deformation of the wedge shaped portion 23 forms a tight seal within the groove 5 and acts to trap the thick portion 13 in the groove 5. The intermediate portion 21 provides space for the deformation of the wedge shaped corner 23.
The angular orientation of the arrowhead portion 15 created by the strip portion 19 cooperates with the disposition of the L shaped portion 9 so that the tip 18 contacts the leg of the L shaped portion, which extends toward the thick portion 13, slides toward the corner formed by the juncture of the legs of the L shaped portion 9 and becomes trapped at the corner of the L shaped portion 9 as the structures 3 and 7 continue to move toward each other. The off center disposition of the tip 18 initiates bending of the strip portion 19 and cooperates with the intermediate portion 21 to cause the strip portion 19 to buckle and the flat surface 17 of the arrowhead portion 15 to seat on the other leg portion of L shaped portion 9, when the groove portion 5 and L shaped portion 9 form the partial enclosure 11 under the continuing application of a minimal closing force. The S shaped cross section of the strip portion 19 formed by the buckling produces a loading on the seating area generally 90°to the pressure loading on the strip portion 19. This loading tends to cancel a similar load applied by the gasket on the opposite side of the closure 11 so that the net force applied by the seal 1 is minimal. The S shaped strip portion 19 will react to pressure from either side to tighten the seal and find a good seat, even if some of the surface of the L shaped portion 9 is damaged. Increased pressure will create a tighter contact pressure between either of the flat surfaces 16 and 17 and the L shaped portion 9, depending on the direction in which the pressure is acting, thereby increasing the sealing action.
The enclosure 11 has a small gap 27 disposed between the L shaped portion 9 and the first structure 3. The gap 27 is smaller than the thickness of the arrowhead portion 15 so that when pressure is applied from the second structure 7 side of the enclosure and builds up to a certain level the arrowhead portion 15 moves across the gap 27 maintaining the seal and continues to do as the pressure continues to increase to a level where the gasket fails due to tearing of the elastomer gasket material.
The enclosure also has a small gap 29 between the portion defining the groove 5, the L shaped portion 9 and the second structure 7. When pressure is applied from the first structure 3 side and reaches a certain level, the pressure attempts to push the strip portion 13 through the gap 29, to do so the strip portion must fold and the folded strip portion is larger than the gap 29 so that under increased pressure the seal is maintained as the sealing action increases until the gasket fails due to tearing of the elastomer gasket material.
The gasket 1 advantageously provides improved sealing characteristics, reduced loading force to form a seal and is more tolerant to seal surface irregularities than traditional O-rings and flat gaskets. The toggle like action allows the gasket to seal even when the structures 3 and 7 are warped.
While the preferred embodiments described herein set forth the best mode to practice this invention presently contemplated by the inventors, numerous modifications and adaptations of this invention will be apparent to others skilled in the art. Therefore, the embodiments are to be considered as illustrative and exemplary and it is understood that the claims are intended to cover such modifications and adaptations as they are considered to be within the spirit and scope of this invention. | A double directional gasket which, when contained within a partial enclosure, forms a double directional seal under low sealing forces due to the toggle like action of the relatively thin central portion of the gasket loading the seating area generally 90 degrees to the pressure loading on the relatively thin central portion. | 4 |
BACKGROUND OF THE INVENTION
The present invention relates to a logic circuit and more particularly a logic circuit especially adapted to be used in VLSI systems.
ECLs (emitter-coupled logic circuits) have been recently widely used in various high-speed electronic circuits. ECLs which are fundamentally differential amplifiers can operate at high speeds and are adapted to be integrated.
When the input signals which are same in phase are applied to a prior art logic circuit, the logical outputs are indeterminate and sometimes the output signals which are opposite in phase may be derived. Therefore a multiplicity of such logic circuits are integrated into a large-scale logic circuit and if the large-scale circuit has some defects, the output signals which are opposite in phase are derived. As a result, it has been impossible to positively detect the internal defects.
SUMMARY OF THE INVENTION
The primary object of the present invention is therefore to provide a logic circuit whose defect can be correctly and readily detected by checking the relationship between the signals derived from the output terminals.
To the above and other ends, the present invention provides an ECL circuit characterized in that a circuit which is adapted to hold the output signals in the same phase relationship when the inputs in the same phase relationship are received is connected to the output circuit of the logic circuit.
According to the present invention, therefore, when the inputs in the same phase relationship are received, the output signals in the same phase relationship are derived. Therefore, when a multiplicity of such logic circuits are integrated into a large-scale logic circuit, the input signals in the same phase relationship are transmitted to and appear at the output terminals so that whether or not the large-scale logic circuit has any defects can be readily and correctly detected by checking the states of the output signals.
The logic circuits in accordance with the present invention are especially adapted to be incorporated in VLSI systems which use a multiplicity of logic circuits.
The above and other objects, effects and features of the present invention will become more apparent from the description of preferred embodiments thereof taken in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a diagram of a prior art ECL circuit;
FIG. 2 is a diagram of a first embodiment of the present invention; and
FIG. 3 is a diagram of a second embodiment of the present invention.
Same reference characters or symbols are used to designate similar parts throughout the figures.
DETAILED DESCRIPTION OF THE INVENTION
Prior to the description of preferred embodiments of the present invention with reference to FIGS. 2 and 3, the prior art will be described briefly with reference to FIG. 1 so as to more distinctly point out the problems thereof.
In FIG. 1 is shown a prior art ECL NAND or AND circuit. Vcc is a positive current source while V EE is a negative current source. A first differential amplifier comprising a pair of transistors T 1 and T 2 and a second differential amplifier comprising a pair of transistors T 3 and T 4 are interconnected between these positive and negative current sources Vcc and V EE , R 1 , R 2 and R 3 are resistors.
Input logic signals which are opposite in phase are applied to a first input terminal A and a second input terminal A', respectively, of the logic circuit. In like manner, differential logic input signals are applied to a third input terminal B and a fourth input terminal B'. The first input terminal A is connected to the base of the transistor T 1 ; the second input terminal A' is connected to the base of the transistor T 2 ; the third input terminal B is connected to the base of the transistor T 3 ; and the fourth input terminal B' is connected to the base of the transistor T 4 .
TABLE 1 shows the truth table in the case of the NAND operation of the logic circuit.
TABLE 1______________________________________A A' B B' C C'______________________________________1 0 1 0 0 11 0 0 1 1 00 1 1 0 1 00 1 0 1 1 0______________________________________
With this logic circuit, in order to accomplish the normal operation, a pair of signals which are opposite in phase must be simultaneously applied to the first and second input terminals A and A'. For instance, when A=1, A'=0. The same is true for the third and fourth input terminals B and B'.
The logic circuit of the type described has the problem that when the input signals are in phase, the output signal is indeterminate.
First Embodiment, FIG. 2
A logic circuit as shown in FIG. 2 is different from the logic circuit as shown in FIG. 1 in that a circuit (to be referred to as "a holding circuit" in this specification) comprising T 5 , T 6 , T 7 , T 8 and T 9 is added.
The transistors T 5 and T 6 constitute a parallel circuit which in turn is connected to an output line connected to a first output terminal C'. In like manner, the transistors T 7 and T 8 constitute a parallel circuit which in turn is connected through the transistor T 9 to an output line connected to a second output terminal C.
The bases of the transistors T 5 and T 7 are connected to the first input terminal A while the bases of the transistors T 6 and T 9 are connected to the second input terminal A'. The base of the transistor T 8 is connected to the third input terminal B.
Next referring further to TABLE 2, the mode of operation of the first embodiment will be described. When the normal input signals which are opposite in phase are applied, either of the transistor T 5 or T 6 is enabled because the transistors T 5 and T 6 are connected in parallel to each other. The transistors T 7 and T 9 are connected in series to each other and the transistor T 9 is connected to the second output terminal C so that either of the transistor T 7 or T 9 is disabled. As a result, the output signals which are opposite in phase are derived. That is, in response to the input signals which are opposite in phase, the output signals which are also opposite in phase are derived. To put into another way, the normal operation of the first embodiment is substantially similar to that of the prior art logic circuit as shown in FIG. 1.
Next the mode of operation when the input signals which are in phase
TABLE 2______________________________________A A' B B' C C'______________________________________1 0 1 0 0 1 0 1 1 0 1 1 0 0 0 0 1 10 1 1 0 1 0 0 1 1 0 1 1 0 0 0 0 1 11 1 1 0 0 0 0 1 0 0 1 1 0 0 0 0 1 10 0 1 0 1 1 0 1 1 1 1 1 1 1 0 0 1 1______________________________________
are applied will be described.
(1) When logic "1" is applied to both the first and second input terminals A and A', the transistors T 1 , T 2 , T 5 , T 6 , T 7 and T 9 are enabled so that the logic "0s" are derived from both the output terminals C and C' except the logic inputs "0s" are applied to the third and fourth input terminals B and B'. When the logic inputs to the third and fourth input terminals B and B' are "0s", the logic outputs "1s" are derived from the output terminals C and C'.
(2) When the logic inputs to the first and second input terminals A and A' are "0s", the transistors T 1 , T 2 , T 5 , T 6 , T 7 and T 9 are disabled so that logic outputs "1s" are derived from the output terminals C and C' regardless of the logic inputs to the third and fourth input terminals B and B'. The reason is that the transistors T 1 , T 2 , T 5 , T 6 , T 7 , T 8 and T 9 are connected in series to the transistors T 3 and T 4 .
(3) Other relationships between the inputs and outputs are shown in TABLE 2. When the inputs to the first and second input terminals A and A' or to the third and fourth input terminals B and B' are in phase, the output signals which are in phase are derived from the output terminals C and C'.
Second Embodiment, FIG. 3
In FIG. 3 is shown a second embodiment of the present invention which is different from the second embodiment as shown in FIG. 2 in that MOS transistors are used and that instead of the load resistors R 1 and R 2 , MOS transistors T 10 and T 11 are used. The mode of operation of the second embodiment may be readily understood from the description of the first embodiment with reference to FIG. 2 so that no further description shall be made in this specification.
So far the present invention has been described in conjunction with the NAND/AND gate, but it is to be understood that when the first and second input terminals A and A' are replaced with the third and fourth input terminals B and B', respectively, while the third and fourth input terminals B and B', with the first and second input terminals A and A', respectively, an NOR/OR gate is provided. So far the present invention has been described in conjunction with the NPN transistors, it is to be understood that PNP transistors may be also used in the present invention.
According to the present invention, when the signals in the same phase are applied to the input terminals, the signals in the same phase are also derived from the output terminals. Therefore, breakdowns of very large scale integrated logic circuits comprising a multiplicity of discrete components can be readily checked only by checking the signals at the output terminals. So far in order to test VLSI systems, an input signal which results in an output signal different from an output signal derived from a normal VLSI system has been applied. Such testing method is not preferable because circuits are increased in size and it is difficult to generate such input signals used for testing. | A logic circuit has two pairs of input terminals to each of which is applied a pair of input signals opposite in phase and a pair of output terminals for deriving a pair of output signals corresponding to the logical states of the two pairs of input signals. The logic circuit is further provided with a holding circuit which is adapted to hold the output signals in the same logical state when a pair of input signal having the same phase are applied to the input terminals. | 7 |
CROSS REFERENCE TO RELATED APPLICATIONS
This application is a continuation of Ser. No. 11/028,754, filed Jan. 3, 2005, which is a continuation of Ser. No. 10/083,711, filed Feb. 26, 2006, which claims priority from U.S. provisional applications 60/271,506 filed Feb. 26, 2001; U.S. provisional application 60/271,602 filed Feb. 26, 2001; and U.S. provisional application 60/271,595 filed Feb. 26, 2001; the entire content of each being incorporated herein by reference.
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH
Not Applicable
BACKGROUND OF THE INVENTION
Stents, grafts, stent-grafts, vena cava filters and similar implantable medical devices, collectively referred to hereinafter as stents, are radially expandable endoprostheses which are typically intravascular implants capable of being implanted transluminally and enlarged radially after being introduced percutaneously. Stents may be implanted in a variety of body lumens or vessels such as within the vascular system, urinary tracts, bile ducts, etc. Stents may be used to reinforce body vessels and to prevent restenosis following angioplasty in the vascular system. They may be self-expanding or expanded by an internal radial force, such as when mounted on a balloon.
Stents are generally tubular devices for insertion into body lumens. Balloon expandable stents require mounting over a balloon, positioning, and inflation of the balloon to expand the stent radially outward. Self-expanding stents expand into place when unconstrained, without requiring assistance from a balloon. A self-expanding stent is biased so as to expand upon release from the delivery catheter. Some stents may be characterized as hybrid stents which have some characteristics of both self-expandable and balloon expandable stents.
Stents may be constructed from a variety of materials such as stainless steel, Elgiloy, nitinol, shape memory polymers, etc. Stents may also be formed in a variety of manners as well. For example a stent may be formed by etching or cutting the stent pattern from a tube or section of stent material; a sheet of stent material may be cut or etched according to a desired stent pattern whereupon the sheet may be rolled or otherwise formed into the desired tubular or bifurcated tubular shape of the stent; one or more wires or ribbons of stent material may be braided or otherwise formed into a desired shape and pattern.
A vessel having a stenosis may be viewed as an inwardly protruding arcuate addition of hardened material to a cylindrical vessel wall, where the stenosed region presents a somewhat rigid body attached along, and to, the elastic wall. The stenosis presents resistance to any expansion of the vessel in the region bridged by the stenosis. Stenoses vary in composition, for example, in the degree of calcification, and therefore vary in properties as well.
A stent may be used to provide a prosthetic intraluminal wall e.g. in the case of a stenosis to provide an unobstructed conduit for blood in the area of the stenosis. An endoluminal prosthesis comprises a stent which carries a prosthetic graft layer of fabric and is used e.g. to treat an aneurysm by removing the pressure on a weakened part of an artery so as to reduce the risk of embolism, or of the natural artery wall bursting. Typically, a stent or endoluminal prosthesis is implanted in a blood vessel at the site of a stenosis or aneurysm by so-called “minimally invasive techniques” in which the stent is compressed radially inwards and is delivered by a catheter to the site where it is required through the patient's skin or by a “cut down” technique in which the blood vessel concerned is exposed by minor surgical means. When the stent is positioned at the correct location, the catheter is withdrawn and the stent is caused or allowed to re-expand to a predetermined diameter in the vessel.
U.S. Pat. No. 4,886,062 discloses a vascular stent which comprises a length of sinuous or “zig-zag” wire formed into a helix; the helix defines a generally cylindrical wall which, in use, constitutes a prosthetic intraluminal wall. The sinuous configuration of the wire permits radial expansion and compression of the stent; U.S. Pat. No. 4,886,062 discloses that the stent can be delivered percutaneously and expanded in situ using a balloon catheter.
U.S. Pat. No. 4,733,665 discloses an expandable intraluminal graft which is constituted by a tubular member formed from a plurality of intersecting elongate members which permit radial expansion and compression of the stent.
EP-A-0556850 discloses an intraluminal stent which is constituted by a sinuous wire formed into a helix; juxtaposed apices of the wire are secured to one another so that each hoop of the helix is supported by its neighboring hoops to increase the overall strength of the stent and to minimize the risk of plaque herniation; in some embodiments the stent of EP-A-0556850 further comprises a tubular graft member to form an endoluminal prosthesis.
The devices cited above are generally satisfactory for the treatment of aneurysms, stenoses and other angeological diseases at sites in continuous unbifurcated portions of arteries or veins.
Within the vasculature however it is not uncommon for stenoses to form at a vessel bifurcation. A bifurcation is an area of the vasculature or other portion of the body where a first (or parent) vessel is bifurcated into two or more branch vessels. Where a stenotic lesion or lesions form at such a bifurcation, the lesion(s) can affect only one of the vessels (i.e., either of the branch vessels or the parent vessel) two of the vessels, or all three vessels. Many prior art stents however are not wholly satisfactory for use where the site of desired application of the stent is juxtaposed or extends across a bifurcation in an artery or vein such, for example, as the bifurcation in the mammalian aortic artery into the common iliac arteries.
In the case of an abdominal aortic aneurysm (“AAA”) in the infrarenal portion of the aorta which extends into one of the common iliac arteries, the use of one of the prior art prosthesis referred to above across the bifurcation into the one iliac artery will result in obstruction of the proximal end of the other common iliac artery; by-pass surgery is therefore required to connect the one iliac artery in juxtaposition with the distal end of the prosthesis to the other blocked iliac artery. It will be appreciated by a person skilled in the art that it is desirable to avoid surgery wherever possible; the requirement for by-pass surgery associated with the use of the prior art prosthesis in juxtaposition with a bifurcation in an artery therefore constitutes a significant disadvantage.
Another example of a vessel bifurcation is the left and right common carotid arteries. These arteries are the principal arteries of the head and neck. Both of the common carotid arteries are quite similar and divide at a carotid bifurcation or bulb into an external carotid artery and an internal carotid artery. In the region of the carotid bulb and the ostium of the internal carotid artery, stenoses present a particular problem for carotid stenting due to the large tapering of the vessel interior from the common carotid artery (both the left and the right) to the internal carotid artery. The region of the carotid bifurcation or bulb happens to be where stenoses most often occur, particularly in the region of the ostium to the internal carotid artery in both of the carotid arteries.
Embodiments of the present invention relate to endoluminal prosthesis (stents) that may be utilized in the region of a bifurcation of vessels. The present invention also embraces stent connecting means for connecting a stent (e.g. a stent which forms part of an endoluminal prosthesis or bifurcated stent) to another stent or portion thereof. Some embodiments of the invention are directed to designs of bifurcated stents and their method of manufacture, as well as apparatuses and methods for introducing prostheses to the vasculature and methods of treating angeological diseases.
All US patents and applications and all other published documents mentioned anywhere in this application are incorporated herein by reference in their entirety.
Without limiting the scope of the invention a brief summary of some of the claimed embodiments of the invention is set forth below. Additional details of the summarized embodiments of the invention and/or additional embodiments of the invention may be found in the Detailed Description of the Invention below.
A brief abstract of the technical disclosure in the specification is provided as well only for the purposes of complying with 37 C.F.R. 1.72. The abstract is not intended to be used for interpreting the scope of the claims.
BRIEF SUMMARY OF THE INVENTION
The present invention includes many different embodiments. Various embodiments of the invention are directed to designs of bifurcated stents and/or the methods and apparatuses utilized to deliver a bifurcated stent to a bifurcation site.
In at least one embodiment, the invention is directed to a bifurcated stent delivery system that includes a unique catheter assembly having a primary and secondary guide wire wherein the secondary guide wire diverges away from the primary guide wire through a split in the catheter housing. The split allows the catheter to deliver a bifurcated stent center first.
The bifurcated stent is an embodiment of the invention that comprises a primary stent section and a secondary stent section. When used with the above catheter, the primary section is delivered center first through the split in the catheter housing. The secondary stent section is then delivered into a secondary vessel according to the predelivery placement of the secondary guide wire.
The bifurcated stent may be a one piece design where the primary and secondary sections are engaged to one another prior to delivery or it may be a two-piece design where the primary and secondary sections are separate and distinct stent bodies that may be optionally engaged to one another during delivery. The primary and secondary stent sections are preferably self-expandable but may be either self-expandable or balloon expandable independent of one another.
In another embodiment of the invention a self-expandable bifurcated stent may be delivered by a catheter having a retractable outer sheath or sleeve that retains the bifurcated stent in a collapsed state. When the sheath is retracted the primary stent section is exposed to self-expand. In at least one embodiment the secondary stent section remains in the collapsed state within the expanded primary stent section until a pusher mechanism is actuated to cause the secondary stent section to self-expand.
In at least one embodiment of the invention, a catheter system is employed wherein two guide wires and at least two balloons are employed to deliver a single piece bifurcated stent. In at least one embodiment, the balloons are substantially parallel to one another and the bifurcated stent is placed over both balloons with a single balloon extending into each section of the bifurcated stent. As a result, the stent branches may be independently guided and expanded. Where a portion of the stent is disposed about both balloons, in some embodiments the balloons may be linked together with a restrictive collar or band of material that will limit the expandability of the balloons to prevent the stent from being over expanded, however in other embodiments the collar may be omitted.
In some embodiments of the invention the catheter may also employ two angioplasty balloons that are initially advanced to the bifurcation site prior to stent delivery.
In at least one embodiment of the invention the bifurcated stent to be delivered is a one piece bifurcation stent comprising a primary stent section and a secondary stent section, the secondary stent section is linked to the primary stent section with one or more flexible linkage members. In at least one embodiment at least four linkage members connect the stent sections. Preferably, the flexible members are substantially S-shaped and/or are selectively annealed.
In at least one embodiment, the invention is directed to a single piece bifurcated stent wherein the primary stent section and the secondary stent section are engaged together by a linkage which allows the bifurcated stent to form distinct support structures on either side of the carina of a bifurcation. Preferably, the linkage comprises at least one strut or connecting member that is shared by both stent sections. In at least one embodiment the linkage is constructed from a selectively annealed metal or other material.
In the various embodiments of the invention portions of a given catheter and/or stent may include radiopaque materials to aid in visual inspection and/or placement of the devices such as during fluoroscopy.
Additional details and/or embodiments of the invention are discussed below.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
A detailed description of the invention is hereafter described with specific reference being made to the drawings.
FIG. 1 is a side view of a distal portion of a stent delivery catheter positioned at a vessel bifurcation.
FIG. 2 is a side view of the catheter of FIG. 1 shown during initial delivery of a primary stent section of a bifurcated stent.
FIG. 3 is a side view of the catheter and bifurcated stent of FIG. 2 where the primary stent section is shown in the deployed state and a secondary stent section is shown in a predeployed state.
FIG. 4 is a side view of the catheter and bifurcated stent of FIG. 3 shown during initial delivery of the secondary stent section.
FIG. 5 is an enlarged side view of the catheter and stent shown in FIG. 4 wherein the primary and secondary stent sections are both shown in a deployed state.
FIG. 6 is a side view of a bifurcated stent delivery system that includes two substantially parallel balloons and guide wires.
FIG. 7 is a side view of a bifurcated stent delivery system wherein the catheter includes a restrictive band where the stent is disposed about both balloons.
FIG. 8 is a side view of a stent delivery system wherein the system includes a pair of angioplasty balloons.
FIG. 9 is a side view of the system of FIG. 6 is shown being positioned at a bifurcation site prior to stent delivery.
FIG. 10 is a side view of the system of claim 9 wherein a first balloon is shown inflated and a primary stent section is shown in an expanded state.
FIG. 11 is a side view of the system of claim 10 wherein a second balloon is shown inflated and a secondary stent section is shown in an expanded state.
FIG. 12 is a side view of the system shown in FIG. 11 wherein both balloons are inflated.
FIG. 13 is a side view of the system of claim 12 wherein the balloons are shown in an uninflated state prior to stent delivery and the sections of the bifurcated stent are shown in a deployed state.
FIG. 14 is an enlarged side view of a bifurcated stent wherein the stent sections are connected by one or more linkage members.
FIG. 15 is an enlarged side view of a bifurcated stent wherein the stent sections are connected by one or more linkage members.
FIG. 16 is a side view of a bifurcated stent wherein the stent sections are connected by an actuated linkage assembly.
FIG. 17 is a side view of a bifurcated stent wherein the primary stent section does not extend substantially beyond the carina when deployed.
DETAILED DESCRIPTION OF THE INVENTION
As indicated above the present invention includes many different embodiments. In some embodiments the invention is directed to various designs of bifurcated stents, their delivery systems and methods of use.
In FIG. 1 an embodiment of the invention is shown which comprises a bifurcated stent delivery system shown generally at 100 . System 100 includes a catheter 10 that is advanced to a bifurcation site 20 along a primary guide wire 12 and a secondary guide wire 14 . In use, the primary guide wire 12 and secondary guide wire 14 are advanced into a body lumen or vessel an advanced into the primary vessel 22 . At the bifurcation site 20 the secondary guide wire 14 is directed into a secondary vessel 24 causing the guide wires 12 and 14 to diverge about the carina 26 . Catheter 10 is advanced along the shared path of the guide wires 12 and 14 until it reaches the carina 26 .
In order to accommodate the divergent path of the secondary guide wire 14 , the catheter 10 includes a spilt area 30 where the secondary guide wire 14 exits the catheter 10 . The spilt area 30 is a gap between two portions of the outer housing 32 of the catheter 10 . The housing 32 may be characterized as a sheath, sleeve, sock or any other assembly suitable for retaining a stent in its collapsed state onto a stent receiving region of a catheter. Some examples of such stent retaining devices are described in U.S. Pat. No. 4,950,227 to Savin et al.; U.S. Pat. No. 5,403,341 to Solar; U.S. Pat. No. 5,108,416 to Ryan et al.; U.S. Pat. No. 5,968,069 to Dusbabek et al.; U.S. Pat. No. 6,068,634, to Cornelius et al.; U.S. Pat. Nos. 5,571,168; 5,733,267; 5,772,669; and 5,534,007 all of which are incorporated herein by reference in their entirety.
In the embodiment shown in FIG. 1 , the housing 32 comprises a distal sleeve 34 and a proximal sleeve 36 . As is more clearly shown in FIG. 2 , sleeves 34 and 36 overlay a stent retaining region 38 of the catheter 10 . Sleeves 34 and 36 may be self-retracting or include one or more pullback mechanisms (not-shown) such as are described in U.S. Pat. Nos. 5,571,135 and 5,445,646 both of which are incorporated herein by reference in their entirety.
In FIG. 1 , the sleeves 34 and 36 overlay the bifurcated stent 50 , shown in FIG. 2 , which is disposed about a stent retaining region 38 . Stent retaining region 38 may include a balloon or other inflatable area for use in expanding and/or seating stent 50 . Stent 50 may be balloon expandable, self-expanding or a hybrid type stent.
In the embodiments shown in FIGS. 2-4 , the bifurcated stent 50 comprises a primary stent section 52 and a secondary stent section 54 . Preferably, both sections 52 and 54 are self-expanding stent bodies though the individual stent sections may have different expansion characteristics as desired. In addition, the sections 52 and 54 of the bifurcated stent 50 may be individual stent bodies that are separately advanced and deployed forming stent 50 once they are fully deployed, or they may be integrally formed or otherwise connected prior to their deployment.
In the embodiment shown in FIG. 2 , the housing portions or sleeves 34 and 36 have been withdrawn from about the bifurcated stent 50 . As the sleeves 34 and 36 are withdrawn from the primary stent section 52 will begin to radially expand in a center first manner through the split area 30 . When the sleeves 34 and 36 are fully withdrawn, such as is shown in FIG. 3 the primary stent section 52 is completely freed from the stent retaining region 38 .
If the stent section 52 and 54 are not integral to each other or otherwise linked prior to delivery, upon expansion of the primary section 52 the secondary section may be advanced along the secondary guide wire 14 and advanced to an opening 62 in the wall 64 of the primary stent section 52 . Opening 62 may be any diameter or shape but preferably is sized to accommodate the outer diameter of the secondary stent section 54 as well as the inner diameter of the secondary vessel 24 .
Whether the secondary stent section 54 is engaged to the primary stent section 52 or separate therefrom prior to deployment, when the secondary stent section 54 is in position at opening 62 and the primary section 52 has been expanded, the secondary stent section 54 is then deployed into the secondary vessel 24 , such as is shown in FIG. 4 . The position of the stent 50 at the bifurcation site maybe visually established through the use of a radiopaque marker 90 , discussed in greater detail below.
In at least one embodiment, where the secondary stent section 54 is at least partially constructed from a shape memory material, such as nitinol, the secondary stent section 54 will self expand according to a preprogrammed shape memory, such that the section both radially and longitudinally expands into the secondary vessel 24 . In some embodiments, catheter 10 may include a pusher assembly 70 that is advanced along the secondary guide wire 14 to trigger expansion of the secondary stent section 54 . Pusher assembly 70 may provide a stimulus which causes the section 54 to expand. Such a stimulus may be in the form of a simple mechanical engagement; delivery of an electrical current; or delivery of a predetermined temperature and/or a predetermined pH, such as by the release of a heated saline bolus. In some embodiments, a separate balloon catheter or other inflation device may be advanced along the secondary guide wire 14 to fully expand and/or seat the secondary stent section 54 .
When both stent sections 52 and 54 are fully deployed, such as is shown in FIG. 5 , the proximal end of the secondary stent section 54 is preferably engaged to the wall 64 of the primary stent section 52 . When fully deployed the primary stent section 52 defines a primary flow path 72 and the secondary stent section defines a secondary flow path 74 that is in fluid communication with the primary flow path via opening 62 .
In an alternative embodiment of the invention, such as is shown in FIG. 6 , system 100 may be provided with catheter 10 that is equipped with at least two balloons, a primary balloon 80 and a secondary balloon 82 , which may be utilized for expansion and/or seating stent sections 52 and 54 .
In the embodiment shown in FIG. 6 , the bifurcated stent 50 may be constructed from stainless steel or other material that necessitates or would benefit from balloon expansion. As with previous embodiments, the catheter 10 includes a pair of guide wires 12 and 14 which are advanced to the bifurcation site 20 and which diverge at the carina 26 with the secondary guide wire 14 advancing into the secondary vessel 24 .
In the embodiment shown in FIG. 6 , during most of the advancement of the catheter 10 the balloons 80 and 82 are positioned together in the substantially parallel orientation shown. However, as the catheter 10 approaches the bifurcation site 20 the distal portion 86 of secondary balloon 82 and secondary stent section 54 are directed along the secondary guide wire 14 into the secondary vessel 24 as shown in FIG. 9 .
In order to ensure that the bifurcated stent will provide adequate support to the vessels 22 and 24 of the bifurcation site, and particularly to the area of the carina 26 , the catheter 10 may include a radiopaque marker 90 . Marker 90 allows a practitioner to advance the catheter 10 to the bifurcation site 20 and visually determine through fluoroscopy or other means that the balloons 80 and 82 and stent sections 52 and 54 are properly positioned about the carina 26 .
Marker 90 may be constructed from any radiopaque material and is preferably part of the bifurcated stent 50 .
Once it is determined that the stent 50 is in proper position at the bifurcation site 20 , the primary balloon 80 is inflated to expand the primary stent section 52 as shown in FIG. 10 . After the initial expansion of the primary stent section 52 , the secondary balloon 82 is inflated to initially expand the secondary stent 54 shown in FIG. 11 .
In some embodiments it may be preferable to first deflate the primary balloon 80 before inflating the secondary balloon 82 . In some embodiments where balloon 80 is deflated prior to inflation of balloon 82 , balloon 80 may be subsequently inflated after inflation of balloon 82 to fully expand the stent and seat it in place within the bifurcation such as is shown in FIG. 12 . Alternatively, balloons 80 and 82 may be inflated simultaneously.
Once both stent sections 52 and 54 are fully expanded, the balloons 80 and 82 are deflated and with drawn from the bifurcation site 20 , such as is depicted in FIG. 13
Because some bifurcated stents may be subject to distortion or damage when over expanded or subjected to high radially outward acting pressure, in some embodiments, such as shown in FIG. 7 , the proximal portion 88 of balloons 80 and 82 , where both balloons are contained within the primary stent section 52 , the catheter 10 may employ a circumferential band 92 that will limit the expandability of the proximal portion 88 of balloons 80 and 82 , thereby preventing over inflation and over expansion of the primary stent portion 54 when both balloons are inflated. Band 92 may be constructed from any minimally or non-expandable material such as polyethyleneterephthalate (PET) or stainless steel.
In some applications, it may be beneficial or necessary to conduct an angioplasty procedure prior to insertion of the bifurcated stent 50 . As a result, in at least one embodiment of the invention, an example of which is shown in FIG. 8 , the catheter 10 may be equipped with a primary angioplasty balloon 94 and a secondary angioplasty balloon 96 . In practice balloons 94 and 96 may be initially advanced to the bifurcation site 20 along guide wires 12 and 14 respectively. Upon reaching the bifurcation site 20 , the balloons 94 and 96 may be inflated to reduce any stenosis or blockage 98 that may be present. After the blockage 98 is reduced, the balloons 94 and 96 may be deflated and advanced along the guide wires 12 and 14 into the respective vessels 22 and 24 thereby allowing balloons 80 and 82 to be positioned at the bifurcation site 20 to delivery the bifurcated stent 50 .
In the embodiments shown in FIGS. 6-13 , the bifurcated stent 50 may be a single piece design, where sections 52 and 54 are engaged to one another prior to and after delivery; or the stent 50 may be a two-piece design where both sections 52 and 54 are independent stent bodies that are separate prior to delivery and which may continue to be separate or which may become engaged to one another during or after delivery.
In embodiments where the stent 50 is a one-piece design, the stent sections may be engaged together by one or more linkage member 102 such as are shown in FIGS. 14-16 . In FIGS. 14 and 15 , the sections 52 and 54 are connected by at least 4 linkage members 102 . In at least one embodiment, the sections 52 and 54 are connected by at least 8 linkage members 102 . Linkage members 102 may be characterized as struts or connecting members 104 that are shared between sections 52 and 54 . In a preferred embodiment, the members 102 are selectively annealed to provide the bifurcated stent 50 with improved flexibility between sections 52 and 54 . By selectively annealing the members 102 , the secondary stent section 52 may be articulated relative to the primary stent section 54 such that the bifurcated stent sections 52 and 54 may be provided with an angular relationship of about 90 degrees, indicated at reference numeral 106 in FIG. 15 , or a more acute angle 108 shown in FIG. 14 . By providing a bifurcated stent 50 that has sections 52 and 54 that may be oriented at a variety of angles, a single stent may be used to address a variety of different angular relationships between vessels of various bifurcation sites within a body. Preferably, the angular relationship between sections 52 and 54 defines an angle of about 10 degrees to about 120 degrees.
In at least one embodiment, the linkage members 102 are provided with a curvilinear or S-shaped configuration such as is best shown in FIG. 15 . The S-shape of the linkage members aids in providing the bifurcated stent 50 with the ability to articulate about vessel junctions of various angles.
In at least one embodiment, shown in FIG. 16 , the sections 52 and 54 of a bifurcated stent 50 are linked by a single linkage member 102 . When inserted at a bifurcation site 20 , the single linkage member is positioned at the carina 26 and acts as a hinge to allow the sections 52 and 54 to be disposed about the carina 26 .
In at least one embodiment of the invention shown in FIG. 17 , stent 50 includes a primary stent section 52 which does not extend distally beyond the carina 26 . As a result the stent 50 may be advanced and positioned at the bifurcation site 20 by a singe guide wire 14 which extends into the secondary branch 24 . Use of a marker 90 allows a practitioner to position the stent 50 by abutting the marker adjacent to the carina 26 and deploying the stent as shown. The stent 50 may include sections that are either balloon expandable, self-expandable, or hybrid expandable as desired. In the embodiment shown, primary stent section 52 is balloon expandable, and secondary stent section 54 is self-expandable.
In addition to being directed to the specific combinations of features claimed below, the invention is also directed to embodiments having other combinations of the dependent features claimed below and other combinations of the features described above.
The above disclosure is intended to be illustrative and not exhaustive. This description will suggest many variations and alternatives to one of ordinary skill in this art. All these alternatives and variations are intended to be included within the scope of the claims where the term “comprising” means “including, but not limited to”. Those familiar with the art may recognize other equivalents to the specific embodiments described herein which equivalents are also intended to be encompassed by the claims.
Further, the particular features presented in the dependent claims can be combined with each other in other manners within the scope of the invention such that the invention should be recognized as also specifically directed to other embodiments having any other possible combination of the features of the dependent claims. For instance, for purposes of claim publication, any dependent claim which follows should be taken as alternatively written in a multiple dependent form from all prior claims which possess all antecedents referenced in such dependent claim if such multiple dependent format is an accepted format within the jurisdiction (e.g. each claim depending directly from claim 1 should be alternatively taken as depending from all previous claims). In jurisdictions where multiple dependent claim formats are restricted, the following dependent claims should each be also taken as alternatively written in each singly dependent claim format which creates a dependency from a prior antecedent-possessing claim other than the specific claim listed in such dependent claim below. | A bifurcated stent includes a first stent section and a second stent section. The first stent section is balloon expandable, has an unexpanded configuration, an expanded configuration, and a tubular wall defining a secondary opening. The secondary stent section is self-expanding and an end of the secondary stent section is engaged to a portion of the tubular wall of the primary stent section defining the secondary opening. The secondary stent section has an unexpanded configuration with a first length and an expanded configuration with a second length where the first length is less than the second length. The secondary stent section is expanded to the expanded configuration after the primary stent section is expanded to the expanded configuration. The secondary stent section forms a portion of the tubular wall of the primary stent section in the unexpanded configuration. | 0 |
CROSS REFERENCES TO RELATED APPLICATIONS
[0001] The present application claims priority to U.S. Provisional Patent Application No. 61/140763, filed on Dec. 24, 2008.
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
[0002] Not Applicable
BACKGROUND OF THE INVENTION
[0003] 1. Field of the Invention
[0004] The present invention relates to a golf club. More specifically, the present invention relates to a golf club assembly.
[0005] 2. Description of the Related Art
[0006] The prior art discloses various methods to assembly golf clubs.
[0007] The joining of shafts to heads in golf club assembly typically utilizes adhesives and cure time. Press fits and crimping are sometimes used. Modern thin and strong materials used in steel shaft make deformation processes difficult. Carbon shafts are also adhesively bonded to shafts and cannot use crimping or press fits because the carbon configuration has relatively low shear and compression capabilities. A quick strong joining method is desired for rate assembly in golf club manufacture.
[0008] BRIEF SUMMARY OF THE INVENTION
[0009] The present invention overcomes these difficulties in steel shaft attachment and carbon shaft attachments.
[0010] The present invention enables quick, clean assembly of golf club shaft to golf club heads. This invention improves the joints contribution to the feel of the club when played in the game of golf.
[0011] One aspect of the present invention is a process for assembling a golf club. The process begins with placing a portion of a golf club head in an ultrasonic welding apparatus. The golf club head has a hosel. Next, a tip end of a shaft is positioned in the hosel. The shaft and the hosel are positioned within the ultrasonic welding apparatus. Next, the hosel and shaft are ultrasonically welded to assemble the golf club.
[0012] Having briefly described the present invention, the above and further objects, features and advantages thereof will be recognized by those skilled in the pertinent art from the following detailed description of the invention when taken in conjunction with the accompanying drawings.
[0013] BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
[0014] FIG. 1 is a perspective view of an ultrasonic machine with a golf club.
[0015] FIG. 2 is an isolated view of a shaft and golf club head joining area.
[0016] FIG. 3 is an enlarged view of an ultrasonic machine with a golf club.
[0017] FIG. 4 is a cross-sectional view along line A-A of FIG. 3 .
DETAILED DESCRIPTION OF THE INVENTION
[0018] The present invention consists of an ultrasonic welding machine, modified to fit the golf club joining area. The machine vibrates the joint area and causes the faying metal surfaces to diffuse slightly into the co-joined opposing metal. The process is applicable for carbon to metal heads through the selection of the metal for application of the ultrasonic vibration motion, thus diffusing the metal into the carbon composite.
[0019] The golf club head is preferably an iron-type golf club head. Alternatively, the golf club head is a wood type golf club head or a putter-type golf club head. The golf club head is preferably composed of a stainless steel material. Alternatively, the golf club head is composed of a titanium alloy material, another iron-alloy material, or a multiple material composition.
[0020] The shaft is preferably composed of a graphite material. Alternatively, the shaft is composed of a stainless steel material, an aluminum alloy material, a titanium alloy material, or a multiple material composition.
[0021] Ultrasonic welding of metal and plastic materials involves transforming electrical signals into mechanical vibrations and vibrating adjacent pieces between a sonotrode and an anvil. The vibrating frictional forces between the pieces weld the adjacent pieces together. A sonotrode and anvil are used to transfer energy from the sonotrode to the interface of the adjacent pieces. Typical frequencies are 20, 30 and 40 kiloHertz. A typical ultrasonic welding device is disclosed in Patrikios et al., U.S. Pat. No. 6,070,777 for an Automated Energy Efficient Ultrasonic Welder, which is hereby incorporated by reference in its entirety.
[0022] The present invention is a new process for assembly of the golf club shafts to the golf club head. The invention decreases the time and facility overhead for production of assembled golf clubs. The invention improves the feel of the joint by removing the epoxy adhesive, which can act to dampen the vibrations that travel from the golf club head to the shaft during impact with a golf ball.
[0023] As shown in FIGS. 1-2 , an ultrasonic apparatus 20 comprises a sonotrode 21 and an anvil 22 . A golf club 30 is placed within the ultrasonic apparatus 20 for assembly. As discussed above, the golf club 30 has a golf club head 35 with a hosel 45 having a bore 47 . The golf club 30 also has a shaft 40 with a tip end 50 . The tip end 50 of the shaft 40 is placed within the bore 47 of the hosel 45 , and then positioned in the ultrasonic apparatus 20 in relation to the sonotrode 21 and the anvil 22 . The sonotrode imparts vibrational energy preferably at at least 20 kiloHertz to an interface of the tip end 50 of the shaft 40 and the hosel 45 to ultrasonically weld the pieces together by diffusing the materials into each other.
[0024] FIGS. 3 and 4 illustrate a slightly different embodiment wherein a separate material 70 is positioned between the interior wall of the hosel 45 and the tip end 50 of the shaft 40 to further enhance the ultrasonic weld. The separate material 70 is preferably a metal, but alternatively is a composite or plastic material.
[0025] Various golf club heads are used with the present invention, and several are disclosed below.
[0026] Gibbs, et al., U.S. Pat. No. 7,163,468 is hereby incorporated by reference in its entirety.
[0027] Galloway, et al., U.S. Pat. No. 7,163,470 is hereby incorporated by reference in its entirety.
[0028] Williams, et al., U.S. Pat. No. 7,166,038 is hereby incorporated by reference in its entirety.
[0029] Desmukh U.S. Pat. No. 7,214,143 is hereby incorporated by reference in its entirety.
[0030] Murphy, et al., U.S. Pat. No. 7,252,600 is hereby incorporated by reference in its entirety.
[0031] Gibbs, et al., U.S. Pat. No. 7,258,626 is hereby incorporated by reference in its entirety.
[0032] Galloway, et al., U.S. Pat. No. 7,258,631 is hereby incorporated by reference in its entirety.
[0033] Evans, et al., U.S. Pat. No. 7,273,419 is hereby incorporated by reference in its entirety.
[0034] Hocknell, et al., U.S. Pat. No. 7,413,250 is hereby incorporated by reference in its entirety.
[0035] From the foregoing it is believed that those skilled in the pertinent art will recognize the meritorious advancement of this invention and will readily understand that while the present invention has been described in association with a preferred embodiment thereof, and other embodiments illustrated in the accompanying drawings, numerous changes, modifications and substitutions of equivalents may be made therein without departing from the spirit and scope of this invention which is intended to be unlimited by the foregoing except as may appear in the following appended claims. Therefore, the embodiments of the invention in which an exclusive property or privilege is claimed are defined in the following appended claims. | A process for ultrasonic welding of a shaft to a golf club head is disclosed herein. The process involves positioning a tip end of a shaft within a bore of a hosel of the golf club head and imparting vibrational energy at least 20 kiloHertz to the interface to ultrasonically weld the shaft to the interior wall of the hosel. The diffusion of materials creates a strong attachment off the shaft to the golf club head. | 1 |
This application claims benefits of Provisional Application Ser. No. 60/183,633 filed Feb. 18, 2000.
FIELD OF THE INVENTION
The present invention relates to a storage device and more particularly, relates to a storage device which may be used in conjunction with a bed.
BACKGROUND OF THE INVENTION
As it has been discussed in the art, it is advantageous to have a storage device which is adjacent the bed. Such a storage device, which is often called a bed pocket, is desirable and useful for the storage of different articles such as reading material, glasses, keys and the like. The bed pocket provides ready access to such articles while preventing damage thereto.
Such bed pockets are known in the art and thus, when they refer to U.S. Pat. No. 4,129,909 which discloses a storage device for the storage of articles. There is shown a sheet like utilitarian member which reaches across and beyond the width of a bed so the pockets in the member hang along both sides of the bed.
A somewhat similar arrangement is shown in U.S. Pat. No. 5,581,829 wherein there are at least two layers having pockets for storing various items. As in the case of the previously mentioned patent, a strap stretches underneath the bed to secure the bed pockets in place. As will be appreciated, when it is necessary to remove the assembly for washing or the like, one must lift the mattress.
SUMMARY OF THE INVENTION
It is an object of the present invention to provide a bed pocket system which is aesthetically pleasing and which can be utilized in a number of different situations.
According to one aspect of the present invention, there is provided a bedding accessory system comprising a pocket formed to have an opening therein, a fastening system comprising a strap member having first and second ends, a first attachment at the first end of the strap member, the first attachment having means for securement to a sheet fabric material, a detachable fastener located at the second end of the strap member, the second fastener having first and second cooperative members, a first one of the members being secured to the second end of the strap member, and a second one of the members of the fastener being secured to the pocket proximate the opening thereto.
The bed pocket is preferably formed of a suitable fabric material and which fabric material is, in one embodiment, coordinated with a skirt which would conventionally surround the frame or box spring of a bed. In a preferred embodiment, the bed pocket is formed to have an outer layer and a lining and as such, can easily be fabricated on equipment known in the art for fabricating such items as pillow cases and the like. Thus, initially the lining and the fabric may be sewn together, folded in two, with the lining being placed interiorly of the fabric to form a finished bed pocket.
As will be discussed hereinbelow, a fastening system is provided for securing the bed pocket to a fabric material such as a sheet of the bed.
BRIEF DESCRIPTION OF THE DRAWINGS
Having thus generally described the invention, reference will be made to the accompanying drawings illustrating an embodiment thereof, in which:
FIG. 1 is a perspective view of a bed pocket system according to one embodiment of the present invention; and
FIG. 2 is a side elevational view of the bed pocket fastening system according to the present invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring to the drawings in greater detail and by reference characters thereto, there is illustrated a bed pocket system in FIG. 1 and which bed pocket system is generally designated by reference numeral 10 . Bed pocket system 10 is utilized in conjunction with a conventional bed designated by reference numeral 12 and which includes a box spring 14 which is mounted on legs 16 . On top of box spring 14 there is provided a mattress 18 . Shown in FIG. 1 is a pillow 20 and a sheet 22 covering mattress 18 .
Secured to sheet 22 is a bed pocket 26 and which will now be discussed in greater detail. Bed pocket 26 is secured by means of a fastening system generally designated by reference numerals 30 and 30 ′.
Fastening system 30 includes a first fastener 34 located at one end of the fastening system 30 . First fastener 34 is preferably formed of a plastic material and includes a first member 36 having a slot aperture 38 at one end thereof. At the other end of first member 36 , there is provided a keyhole aperture generally designated by reference numeral 40 . Secured to first member 36 is a flexible tongue member 42 which has a locking projection 44 extending outwardly therefrom and which locking projection is shaped to fit within keyhole aperture 40 . This type of fastener is that which is sometimes referred to as a garter fastener.
Secured to first member 36 through slot aperture 38 is a strap member 46 which, in the illustrated embodiment, includes hook members 48 used in a hook and loop type of fastener such as is commonly marketed under the trademark VELCRO.
At the opposite end, strap 46 is secured to a plastic clip 52 for reasons which will become apparent hereinbelow.
Also secured to strap 46 is an elastic strap 54 which includes a fastener 56 at the opposed end thereof. Fastener 56 is similar to fastener 34 and thus includes a first member 58 having a slot aperture 60 formed therein and through which elastic strap 54 is secured. Similarly, there is provided a keyhole aperture (not shown) designed to receive locking projection 66 of tongue member 64 .
There is also provided a plastic clip 74 designed to engage plastic clip 52 . In this respect, plastic clip 52 may be of the female type and plastic clip 74 of the male type. These clips are well known and use a pair of outwardly extending prongs on the male portion to mate with the recesses on the female portion.
As shown in FIG. 2, a strap 72 is connected to male plastic clip 74 and also is secured to bed pocket 26 .
Fastening system 30 ′ is substantially identical to fastening system 30 and thus will not be described herein.
Bed pocket 26 may be, as previously discussed, any suitable type and preferably is designed to match the bed material. Alternatively, bed pocket 26 could be any suitable container which could be detached and used as required—as a youngster's knapsack or the like.
It will be understood that the above described embodiment is for purposes of illustration only and that changes and modifications may be made thereto without departing from the spirit and scope of the invention. | A bedding accessory system which comprises a bed pocket having an opening therein and a fastening system which can be secured to the sheets of a bed without moving the mattress. The fastening system is a multipurpose one and can be adapted for different uses. | 0 |
PRIORITY CLAIM
[0001] The present application claims priority under 35 U.S.C. §119(e) to:
U.S. Provisional Patent Application No. 61/115,389, filed Nov. 17, 2008, titled “X-Ray Opaque Coatings and Application,” incorporated by reference herein; U.S. Provisional Patent Application No. 61/115,392, filed Nov. 17, 2008, titled “Glycidyl Ether of Di-Iodinated Phenol, a New Epoxy Diluent Useful for Formulation of X-Ray Opaque Coatings,” incorporated by reference herein; and U.S. Provisional Patent Application No. 61/119,170, filed Dec. 2, 2008, titled “Highly Filled X-Ray Opaque Coating Materials Containing Iodinated Reactive Epoxy Diluent,” incorporated by reference herein.
TECHNICAL FIELD
[0005] The current disclosure relates to an X-ray opaque coating, and in particular, an X-ray opaque coating containing an epoxy resin formed from an iodinated phenol containing a glycidyl ether. The current disclosure also relates to devices or materials containing such a coating and methods of forming such a coating.
BACKGROUND
[0006] Control of X-rays via X-ray opaque materials is useful in at least two situations: the protection of microelectronics and decreasing exposure of X-rays to humans and/or other animals. X-rays may damage many materials, such as microelectronics, as well as harm humans and other animals, particularly medical personnel who are frequently exposed to X-rays. Use of X-ray opaque materials may prevent or lessen these types of damages. For example. X-ray opaque materials may be used to prevent non-destructive investigation of hardware, such as microelectronics. This non-destructive investigation may be used to copy the hardware for commercial purposes or to discover confidential hardware designs and components.
[0007] Current techniques for protecting microelectronics from damaging X-rays, electromagnetic interference (EMI) and inhibiting examination and/or reverse engineering of components utilizes a multilayer coating including layers of resin, ceramic, metal or metal alloys, and/or an opaque porous silica-containing ceramic layer that is applied directly onto the microelectronics. However, the design and manufacture of these multi-coatings are both expensive and difficult. As a result, device manufacturers have limited the use of these protective coatings to a particular area of the microelectronics, this technique generally referred to as spot shielding, which only protects a portion of the device. In the event that damaging x-rays are present, or there is an EMI, device failures in areas that are not protected may cause the entire device to fail. Further, spot shielding may not protect the device from investigation or from reverse engineering tactics.
[0008] In the medical and dental field, X-ray opaque materials may be used to protect a subject (e.g., patient, technician, doctor, nurse, etc.) from errant X-ray penetration. The X-ray opaque materials may also be used for dental adhesives and fillers or bone adhesives, fillers, and/or substitutes, and may have properties that allow for proper imaging of the site of use. However, current X-ray opaque materials are limited in such uses because the components used to manufacture the opaque materials are required to have low toxicity and may benefit from other properties that are not easily obtained.
SUMMARY
[0009] According to a first embodiment, the disclosure relates to an X-ray opaque coating containing an epoxy resin formed from an iodinated phenol covalently bonded to a glycidyl ether.
[0010] According to a more particular embodiment, this iodinated phenol covalently bonded to a glycidyl ether may include iodinated bisphenol A. According to a more specific embodiment, the iodinated bisphenol A may include a diglycidyl ether of tetraiodobisphenol A.
[0011] According to another particular embodiment, the iodinated phenol covalently bonded to a glycidyl ether may include a glycidyl ether of mono-iodophenol, bis-iodophenol, tri-iodophenol, or combinations thereof. In a more particular embodiment, it may include a combination of two or more of these three compositions in which at least 50% of the total (e.g. by weight or concentration) is the glycidyl ether of bis-iodophenol.
[0012] According to an additional particular embodiment, the iodinated phenol covalently bonded to a glycidyl ether may include both a diglycidyl ether of tetraiodobisphenol A and a glycidyl ether of bis-iodophenol.
[0013] The above compositions, in some embodiments, may include an X-ray opaque inorganic filler.
[0014] According to a second embodiment, the disclosure relates to a method of forming an X-ray opaque coating, including any X-ray opaque coating described in the first embodiment above. The method may include forming an epoxy resin containing iodinated phenol covalently bonded to a glycidyl ether. The resin may be cured by combining the iodinated phenol covalently bonded to glycidyl ether and a curing agent. A diluent or an X-ray opaque inorganic filler may also be added.
[0015] According to a third embodiment, the disclosure relates to an electronic component including a substrate and at least one device coupled to the substrate with an obfuscation layer disposed over the substrate for obscuring the device from an X-ray source. The obfuscation layer may include an X-ray opaque coating, such as any X-ray opaque coating described in the first embodiment above. According to a more specific embodiment, the electronic component may also include at least one connection which may also be obscured by the X-ray opaque coating.
[0016] According to a fourth embodiment, the disclosure provides a method of obscuring at least a portion of an electronic component by depositing an obfuscation layer over a substrate of the electronic component to obscure at least one device coupled to the substrate from an X-ray source. The obfuscation layer may include an X-ray opaque coating, such as any X-ray opaque coating described in the first embodiment above. The obfuscation layer may be formed, for example as a sheet, prior to being deposited.
[0017] The above summary provides a general outline of particular embodiments of the invention. For a better understanding of the invention and its advantages, reference may be made to the following description of exemplary embodiments.
BRIEF DESCRIPTION OF THE DRAWINGS
[0018] A more complete understanding of the present embodiments and advantages thereof may be acquired by referring to the following description taken in conjunction with the accompanying drawings, in which like reference numbers indicate like features, and wherein;
[0019] FIG. 1 illustrates an example cross-sectional view of an electronic component with an obfuscation layer, is accordance with embodiments of the present disclosure;
[0020] FIG. 2 shows an example of the obfuscation layer obscuring features of an integrated circuit, in accordance with embodiments of the present disclosure.
DETAILED DESCRIPTION
[0021] Specific embodiments of the invention and their advantages are best understood by reference to FIGS. 1 and 2 , wherein like numbers are used to indicate like and corresponding parts.
[0022] The present disclosure provides an X-ray opaque coating containing an epoxy resin formed from an iodinated phenol containing glycidyl ether as well as devices or materials including such a coating and methods of forming such a coating. According to some embodiments, the coating may also contain one or more X-ray opaque fillers. The epoxy resin may be a cured epoxy resin. The coating may be used to protect materials (e.g., microelectronics, hardware, etc.) and humans or animals from X-rays, and in particular, X-rays that may cause damage to the protected material, human or animal, or from X-rays that allow visualization of microelectronics hardware, electronic data storage devices, and other items. The coatings may also be used in medical and dental industries, for example as a shield to control diagnostic X-rays.
[0023] Referring to FIGURE 1 , a cross-sectional view of an electronic component 100 (e.g., circuit boards, chips, or other micro- or nanoelectronics) with an obfuscation layer 108 containing an X-ray opaque coating is shown, in accordance with embodiments of the present disclosure. Electronic component 100 may include active and/or passive devices 104 on top of a substrate 102 . Devices 104 may be housed in housing 106 which includes an obfuscation layer 108 . The epoxy resin may provide a robust material that is both thermally and chemically stable, while the use of fillers in the X-ray opaque coating may enhance the properties of the epoxy material.
[0024] When electronic component 100 is exposed to X-rays, some X-rays may be scattered, while most are absorbed by obfuscation layer 108 . The obfuscation layer 108 may shield devices 104 from the X-rays which may damage the devices. In the same or alternative embodiments, obfuscation layer 108 may protect devices 104 from X-rays that may be used to reverse engineer or obtain information regarding devices 104 .
[0025] Although shown here in FIG. 1 as a coating for protecting, shielding, or otherwise obscuring hardware components, obfuscation layer 108 may be used for other applications including, for example, the medical field, where obfuscation layer 108 may be used to protect: humans (e.g., nurses, X-ray technicians, patients, doctors) from errant X-ray exposure. In alternative embodiments, obfuscation layer 108 may be used as dental or bone adhesives, fillers, and/or substitutes.
[0026] In one embodiment, obfuscation layer 108 may include a diglycidyl ether of tetraiodobisphenol A (I):
[0000]
[0000] An example synthesis of the diglycidyl ether of teraiodobisphenol A (I): Is provided in Example 1 below.
[0027] In another embodiment, obfuscation layer 108 may include a glycidyl ether of bis-iodinated phenol (II), for example;
[0000]
[0000] An example synthesis of this glycidyl ether of bis-iodinated phenol (II) is provided in Example 2 below. The glycidyl ether of mono-, bis-, or -tri-iodinated phenol and combinations thereof may have a lower viscosity than the diglycidyl ether of tetraiodobisphenol A (I). Although only one variant of the compound is shown above, various isomers may also be present. Further, although a bis-iodinated version is shown, mono- and tri-iodinated variants may also be used. According to one embodiment, a mixture of isomers of the glycidyl ether of mono-, bis- and tri-iodinated phenol may be used. In a more specific embodiment, the bis-iodinated form may be predominant (e.g. more than 50%, more than 90%, or between 50% and 90% of the total may be the bis-iodinated form). This form may offer more degrees of freedom and thus best enhance the processing window, final properties, and filler content of the final epoxy resin forming the X-ray opaque coating,
[0028] According to a specific embodiment, the glycidyl ether of iodinated phenol may be used as a low viscosity diluent in combination with the diglycidyl ether of tetraiodobisphenol A (I).
[0029] According to additional embodiments, other compounds containing a covalently attached iodine and a glycidyl ether may be used. The compounds may be used alone or in combinations. Some may serve as diluents.
[0030] In some embodiments, obfuscation layer 108 may also contain one or more X-ray opaque inorganic fillers. These fillers may be included in the epoxy resin. Example fillers include, but are not limited to potassium iodide, bismuth iodide, barium chloride, barium iodide, barium sulfate, lead, lead iodide, lead acetate, lead oxide, gold flake and the like. Fillers may also enhance the thermal mechanical properties of obfuscation layer 108 . According to one embodiment, the X-ray opaque coating may be highly filled, for example, it may include up to 85% filler by weight.
[0031] Epoxy resins in obfuscation layer 108 may be cured using any suitable curing techniques. Amine curing agents, such as triethylenetetraamine (TETA) and the like may be added. The amount of curing agent added may be determined by the stoichiometry of the curing agent and the resin(s).
[0032] In some embodiments, obfuscation layer 108 may vary in thickness across electronic component 100 depending on, for example, particular areas that need to be particularly protected, shielded, or otherwise need to be hidden from view. Random variations in the thickness of obfuscation layer 108 across electronic component 100 may also improve its X-ray opacity as compared to more uniform layers. In the same or alternative embodiments, obfuscation layer 108 may be have a uniform thickness across electronic component 100 , where the thickness is suitable to protect, shield, or otherwise hide devices 104 or the connections (e.g., traces, vias, bond wires, etc.) between devices 104 . In still other embodiments, obfuscation layer 108 may be thicker in areas where greater obfuscation is desirable. The overall size of the obfuscation layer may be sufficient, to obscure desired devices 104 or connections.
[0033] Although a single obfuscation layer is shown in FIGURE 1 , multiple layers may be used for the same electronic component 100 . Further, although only a top obfuscation layer is shown, the layer may be placed on any surface and multiple surfaces may have obfuscation layers.
[0034] Obfuscation. layer 108 may be formed by one or more sheets of X-ray opaque coating. These individual sheets or the total thickness of X-ray opaque coating may be less than is required with current X-ray opaque coatings. For example, the X-ray opaque coating may be as thin as approximately 30-40 mil. Inclusion of a glycidyl ether of an iodinated phenol or other low-viscosity diluent may allow the use of less material overall to form an obfuscation layer.
[0035] Obfuscation layer 108 may be coupled to electronic component 100 . According to some embodiments, obfuscation layer 108 , devices 104 , or both may be housed in a substantially or partially hermetic package such as, for example, a T/R module. In some embodiments the obfuscation layer 108 may be coupled to devices 104 . In other embodiments, it may be spaced away from one or more devices 104 . This may allow improvements in RF capabilities of electronic component 100 .
[0036] Accordingly to specific embodiments, the X-ray blockage may be measured by luminance of the X-ray opaque coating. X-ray blockage may also be measured as compared to a baseline material, such as a phenol-based epoxy. In one example, X-ray blockage may be increased as much as 26% compared to uniodinated material of similar thickness. Addition of an iodinated diluent may increase X-ray blockage.
[0037] Certain X-ray opaque coatings of the current disclosure, particularly those containing a glycidyl ether of an iodinated phenol, may have a high refractive index. Such coatings may be useful for optical coating, refractive index matching materials, optical waveguides, and the like.
EXAMPLES
[0038] The present invention may be better understood through reference to the following examples. These examples are included to describe exemplary embodiments only and should not be interpreted to encompass the entire breadth of the invention.
Example 1
Formation of Diglycidyl Ether of A Tetraiodobisphenol A Molecule
[0039] 33 grams (0.15 mo1) of bisphenol A was dissolved in 1000 mL of aqueous ammonium hydroxide. A solution of 150 grains of potassium iodide, 100 grams of iodine (0.79 mol), and 800 ml, of water was added to the bisphenol A and aqueous ammonia hydroxide mixture over a period of an hour at room temperature. This caused a reaction in which the iodine disappears in the solution. The reaction was rapid, non-thermic and easy to control. The reaction was continued until an excess of iodine was colorimetrically evident.
[0040] Next, after 24 hours, an aqueous hydrochloric acid (HQ) was added to achieve a pH of 9 and the solid was vacuum filtered to yield a crude product. Next, the filtered solid was dissolved in aqueous ammonium hydroxide. Aqueous HCl was added to adjust the pH to 5. The precipitate was subsequently filtered and dried to yield 84 grams of product. The product had IR and Proton NMR spectra as well as elemental analysis results consistent with tetraiodobisphenol A (III);
[0000]
[0041] 60 grams of tetraiodophisphenol A (III) (0.16 mol) was mixed with a gross excess of 60 ml of epicholorohydrin and heated to 90° C. and stirred to dissolve the mixture to a homogenous solution. A solution of 8.9 grams of potassium hydroxide (0.16 mol) in 50 mL of methanol was added to the heated solution, over a period of 30 minutes. The resultant slurry was subsequently stirred and refluxed for an additional hour and cooled.
[0042] The cooled mixture was mixed with a mixture of chloroform and hexane and then filtered using a Celite filter pad. The filtered mixture was concentrated using heat and vacuum and yielded about 64 grams of viscous resin having a IR and Proton NMR as well as epoxy equivalent weight indicating that the diglycidyl ether of tetraiodobisphenol A (I) had been formed:
[0000]
Example 2
Formation of Glycidyl Ether of A Diiodinated Phenol Molecule
[0043] 125 grams of phenol (1.33 mol) in two and a half liters of aqueous ammonium hydroxide was added to 400 grams of an aqueous mixture of potassium iodide and 335 grams of iodide (2.6 mol), which resulted in a rapid reaction that resulted in decolorization of the iodine mixture after addition of the phenol. A small aliquot of the reaction product was acidified and subjected to a gas chromatography/mass spectrometry (GC/MS) analysis, which showed the organic portion of the reaction mixture to be a mixture of single isomers of a mono- and/or tri-iodinated phenol and isomers of a bis-iodinated phenol. The remaining reaction product was adjusted to pH 6 with aqueous HCl and extracted with dichloromethane then dried over sodium sulfate. Distillation at reduced pressure yielded 350 grams of product that boiled at 75-90° C. at 1 Torr. This product was primarily bis-iodinated phenol (IV) with some mono-iodinated phenol:
[0000]
[0044] 311 grams of the primarily bis-iodinated phenol solution (IV) (135 mol) was: mixed with an. excels of 280 grams of epicholorohydrin and subsequently heated to about 80° C. After the heating step, a solution of 53.5 grams sodium hydroxide (1.34 mol) in methanol was slowly added over an hour. After an additional hour of gentle reflux at 80° C. reaction, mixture contained both a solid sod a liquid phase. This mixture was cooled and diluted in methylenechloride/hexane, filtered, and evaporated, resulting in a crude product. The crude product was purified by fractional distillation (boiling point 110-150° C. 0.1 Torr), yielding 265 grams of a water while liquid material having isomers of the glycidyl ether of mono-iodophenol and the glycidyl ether of bis-iodophenol (II);
[0000]
[0045] Elemental analysis: of the product was consistent with Its chemical formula. The product has a refractive Index of 1.6105.
Example 3
X-Ray Opaque Coating Testing
[0046] A thermoset epoxy resin formed from an iodinated phenol containing a glycidyl ether was used as an obfuscation layer and was placed relative to an integrated circuit, similar to the cross-sectional illustration of FIG. 1 . The integrated circuit and the obfuscation layer were imaged using X-rays.
[0047] Specifically, 10 grams of tetraiodobisphenol A (III) was mixed with 1.5 grams of phenylglycidylether to aid processing 0.8 grams of TETA was added and the mixture was heated to 100° C. for 24 hours. Elemental analysis of the resulting material revealed the following composition: C-36.3%, H-3.6%, N-2.5%, and 1-48.9%. The material was opaque to hard and soft X-rays.
[0048] For example, FIG. 2 shows an image of a integrated circuit with vias and bonds that, are obscured due to the use of an obfuscation layer containing a cured iodinated bisphenol A epoxy with a bismuth iodide (BiI 3 ) filler. As FIG. 2 shows, the features of the circuit are difficult to distinguish. Similar results have been obtained with other obfuscation layers containing epoxy resins formed from iodinated phenol containing a glycidyl ether.
[0049] Although only exemplary embodiments of the invention are specifically described above, it will be appreciated that modifications and variations of these examples are possible without departing from, the spirit and intended scope of the invention. For example, in specification particular measurements are given. It would be understood by one of ordinary skill in the art that in many instances other values similar to (such as about or approximately), but not exactly the same as the given measurements may be equivalent and may also be encompassed by the present invention. | The disclosure relates to an X-ray opaque coating containing an epoxy resin including an iodinated phenol covalently bonded to a glycidyl ether. Iodinated phenol covalently bonded to a glycidyl ether may include iodinated bisphenol A, such as tetraiodobisphenol A, a glycidyl ether of mono-iodophenol, bis-iodephenol, tri-iodophenol, or combinations thereof. The coating may include an X-ray opaque inorganic filler. The disclosure also relates to an electronic component including a substrate and at last one device coupled to the substrate with an obfuscation layer disposed over the substrate for obscuring the device from an X-ray source. The obfuscation layer may include an X-ray opaque coating. The disclosure additionally relates to- a method of obscuring at least a portion of an electronic component by depositing an obfuscation layer that may includes m X-ray opaque coating and a method of forming an X-ray opaque coating. | 7 |
FIELD OF THE INVENTION
The present invention relates to a system for controlling vehicle components, e.g., for steering a vehicle, according to the “Drive by Wire” principle.
BACKGROUND INFORMATION
The fundamental characteristic of a “Drive by Wire” vehicle is that a direct, mechanical connection exists neither between the foot controls and the corresponding components (gas, brake, clutch), nor between the steering wheel and the wheels coupled to it. The control measures taken by the driver are no longer directly converted into mechanical displacements, but are picked up by sensors at the pedals and the steering wheel, electronically processed by control computers, and transmitted as an electrical, controlled variable to the corresponding actuators.
The advantages of a “Drive By Wire” system include, inter alia, the increase in passive safety, since, e.g., the elimination of a steering column excludes it from intruding into the vehicle interior. In addition, the comfort of the vehicle can be improved, because, e.g., it is possible to freely select the restoring torque at the steering wheel and vary the transmission ratio between the steering wheel and the wheels coupled to it. There are also design advantages. This facilitates, for example, the construction of right-hand/left-hand steering designs, as well as their selection, and also facilitates the conversion to driving-school vehicles or disabled-friendly vehicles. Furthermore, “Drive By Wire” systems simplify the system integration of devices such as a vehicle stability control system, anti-lock braking system, traction control system, automatic speed control, etc., which means that the costs can be correspondingly reduced.
On the other hand, a “By Wire” system has, however, the problem that a transition into a safe state is not ensured in the event of a fault in one of its components. In contrast to, e.g., conventional power-assisted steering, which still retains the basic steering function in the event of a fault that leads to the failure of the servo assistance of the steering, the malfunction of a component in a “By Wire” system can have fatal consequences if design or conceptional safety measures are not taken.
A hydraulic steering device is described in U.S. Pat. No. 4,771,846. The hydraulic steering device is supplied with pressurized hydraulic fluid by a pump, via a proportional valve. The proportional system is controlled with the aid of an electromagnet, using signals picked up by a steering-angle sensor. In this context, the proportional valve is controlled so that the value specified by the steering-angle sensor is set at the steered wheels. In this case, it is disadvantageous that the entire steering system fails when the proportional valve ceases to operate.
A further steering system is described in German Published Patent Application No. 35 36 563, where the movement of a steering handwheel starts an electric motor, using switching electronics. The electric motor drives a pump, which is connected to working chambers of a working cylinder. In this context, the rotational direction of the pump determines the direction in which the working cylinder is displaced. This system is also not redundant and runs the risk of complete failure.
In addition, German Published Patent Application No. 40 11 947 describes a steering system for two steerable wheels, where the wheels can be steered independently of each other. The individual wheels are driven by a servomotor, which is powered by an electronic control unit. In this case, there is also the danger of the vehicle no longer being steerable in response to the servomotor or the electronic control unit failing.
A steering system, which controls at least two independent motors with the aid of at least two independent control units, is described in German Published Patent Application No. 42 41 849. Safe operation is ensured by fault monitoring and redundancy in the motors. A fault-monitoring device prevents a defective control unit from controlling the steering elements. However, it is disadvantageous that incorrect steering is triggered by any undetected faults in the control units.
It is an object of the present invention to provide a “Drive By Wire” system, e.g., for steering a vehicle, which passes over into a safe operating state in the event of one of its components malfunctioning in a manner that is critical with regard to safety.
SUMMARY
This object is achieved by providing a system as described herein. One example embodiment of the system of the present invention accordingly includes at least one steerable wheel, a steering wheel or equivalent steering device, an odd number of more than one intercommunicating control computers which are each connected to at least one first sensor detecting a movement or actuation of the steering wheel or steering device and to at least one second sensor directly or indirectly detecting the position of the at least one steerable wheel, a first actuator and a second actuator which are each mechanically coupled to the at least one steerable wheel and may each be controlled by one of the control computers, a first voter-basis discriminator that is assigned to the first actuator, and a second voter-basis discriminator that is assigned to the second actuator. Each of the control computers transmits a first signal to the first voter-basis discriminator and a second signal different from the first signal to the second voter-basis discriminator. The actuator, the assigned voter-basis discriminator of which receives the first signal from the majority of the control computers, is actively controllable by its assigned control computer. Using model calculations and the measured values acquired by the sensors, the control computers ascertain their own state and the state of the system and, in each case, effect a switchover from the active control computer to the control computer assigned to the other actuator if the system function shows deviations from the model expectations of a majority of the control computers.
Therefore, the system components that are critical with regard to safety are configured with redundancy so that, in the case of a malfunctioning component, the system automatically switches over to a corresponding component that works correctly. In the control computers, a routine may be implemented which allows each controlling, control computer to formulate and transmit a switchover request to the other control computers, whereby the other control computers change their signals received by the voting-basis discriminators, so that another control-enabled control computer assumes control in the system, by then controlling the actuator assigned to it.
An example embodiment of the system according to the present invention provides for the control computers intercommunicating via a CAN bus. This may be advantageous, since a CAN bus operates in a substantially fault-tolerant manner, and independently of the CPU.
Another example embodiment of the system according to the present invention is characterized in that the actuators each possess a hydraulic control unit having a double-acting steering cylinder, the two cylinder chambers of each steering cylinder being interconnectable by a steering bypass valve. In each case, this arrangement may allow one of the redundant steering cylinders to be switched on or switched off in a simple and reliable manner. In this context, the voter-basis discriminators control the steering bypass valves and thus establish which hydraulic circuit is active at any one time.
Another example embodiment of the present invention provides for the pressure in each of the two cylinder chambers of the dual-acting steering cylinder being adjustable, using a proportional valve, a separate pressure sensor being connected to each of the two cylinder chambers. In this context, each steering cylinder may be assigned its own pump for providing the necessary supply pressure.
The outlet of the pump may be connected to a pressure reservoir, via a non-return valve. Therefore, the pump may not be continuously run during the operation of the vehicle. Along these lines, a pressure sensor may be provided for measuring the supply pressure, the pump being limited by the actively-controlling control computer in response to a predefined pressure value being reached.
In addition, a branch leading into a hydraulic-fluid tank may be connected to a pump bypass valve, between the outlet of the pump and the non-return valve. This allows the pump to start up without counterpressure from the system. In the case of an electric pump, this may prevent high starting currents.
A further example embodiment according to the present invention provides for one of the control computers controlling a steering-torque motor connected to the steering wheel, in order to simulate a restoring torque. In this context, the pressure difference between the two cylinder chambers of the double-acting steering cylinder is used as a basis for calculating the restoring torque at the steering wheel.
The system of the present invention may include a brake system, as well. The system may additionally include: a brake-pedal mechanism; a first wheel-brake cylinder and a second wheel-brake cylinder, which each belong to different brake circuits that each have a hydraulic control unit; as well as a number of third sensors corresponding to the odd number of more than one control computers; each third sensor detecting the position of the brake pedal and being connected to one of the control computers, so that each brake circuit is assigned a different control computer, by which the corresponding brake circuit may be controlled according to the “Brake By Wire” principle. In this case, the control computers and voting-basis discriminators present for the steering, as well as parts of the hydraulics, may be used for the brake system as well.
The brake system may be divided into two brake circuits that are independent of each other, each brake circuit having two wheel-brake cylinders, of which the one wheel-brake cylinder is assigned to a front wheel and the other wheel-brake cylinder is assigned to a rear wheel on the opposite side of the vehicle.
The present invention is explained in detail below with reference to Figures that represent an exemplary embodiment.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic view of a system according to the present invention, for electrohydraulically steering and braking a vehicle according to the “Drive By Wire” principle.
FIG. 2 is a schematic view of the components of the steering hydraulics used in the system illustrated in FIG. 1 .
FIG. 3 is a schematic view of the components of the brake hydraulics used in the system illustrated in FIG. 1 .
DETAILED DESCRIPTION
The “Drive By Wire” system schematically illustrated in the Figures includes two subsystems, namely, a steering system and a brake system. Therefore, the “Steer By Wire” and “Brake By Wire” subsystems differ from a functional standpoint. The actuators for steering and braking are both present in duplicate so that, in response to the failure of one actuator, the system may switch over to the other.
Three intercommunicating control computers 1 , 2 , 3 and two voter-basis discriminators 4 , 5 , which are also referred to as “voters”, form the center point of the system illustrated. Each of the control computers 1 , 2 , 3 is equipped with its own sensors 6 , 9 , 12 ; 7 , 10 , 13 ; 8 , 11 , 14 in order to pick up the control taken by the driver, using the steering wheel and the brake pedal, and to detect the steering angle of the wheels. In addition, sensors are present for detecting the power-supply state. In this context, each of the control computers also has its own auxiliary power supply. A CAN bus 15 , which functions in a substantially fault-tolerant and CPU-independent manner, is used for communication between control computers 1 , 2 , 3 .
Control computers 1 and 3 have control over their own hydraulic steering and brake circuits. Either just the circuit of control computer 1 or just the circuit of control computer 3 is active with regard to the steering, whereas two brake circuits may be always used. Control computer 1 controls the left front (reference numeral 16 ) and right rear wheel-brake cylinders, while control computer 3 correspondingly controls the front right (reference numeral 17 ) and left rear wheel-brake cylinders, so that, in case a brake circuit fails, the basic functioning of the brakes may still be ensured. Reference numerals 18 and 19 each designate a hydraulic control unit, to which, in addition to the wheel-brake cylinders of a brake circuit, a double-acting steering cylinder 20 and 21 is connected, respectively.
On one hand, control computer 2 is used as a control computer for the two control-capable computers 1 and 3 and therefore allows, for the first time, a voter-basis decision in voter 4 and 5 . On the other hand, it controls a steering-torque motor that simulates a restoring torque on steering wheel 22 .
Voter-basis discriminators (voters) 4 , 5 control steering bypass valves 23 (cf. FIG. 2) and thus stipulate, which hydraulic steering circuit is currently active. Each of the two voter-basis discriminators 4 , 5 receives a 1-bit input signal from each of the three control computers 1 , 2 , 3 . From the point of view of the specific control computer i, the two signals that it outputs to voter-basis discriminators 4 , 5 are the inverse of each other, i.e., it either transmits a low signal (E 1i =0) to voter-basis discriminator 4 and a high signal (E 2i:=E 1i =1) to voter-basis discriminator 5 , or vice versa. Therefore, first subscripts (i) are omitted below.
Voter-basis discriminators 4 , 5 determine their output signal A 1 and A 2 in accordance with their input variables E 1 through E 3 and E 1
through E 3
from the following equations: A 1 := ( E 1 ⋀ E 2 ) ⋁ ( E 2 ⋀ E 3 ) ⋁ ( E 1 ⋀ E 3 ) A 2 := ( E 1 ⋀ E 2 ) ⋁ ( E 2 ⋀ E 3 ) ⋁ ( E 1 ⋀ E 3 )
Therefore, in each case, the hydraulic steering circuit, the corresponding voter-basis discriminator 4 or 5 of which receives a high signal from at least two control computers, is active. Each control computer may determine which one of them is actively in control at the very moment, by exchanging status data via CAN bus 15 .
Control computers 1 , 2 , 3 may include microcontrollers. The control software includes a plausibility check, which identifies faults in the actuators. To this end, the driver's command, i.e., the control command issued by the driver, using the steering wheel and/or the brake pedal, is on one hand transmitted to the specific actuator system and, on the other hand, used in model calculations in the control computers. The values supplied by the model calculations are compared to the measured values of the actuator system. If the measured values of the actuator system are inside a specifiable tolerance range, then the actuator system is functional.
The control software is configured to classify an occurring fault with regard to its effect on the entire system, i.e., it is determined if the fault or faults are tolerable or endanger the operational safety of the vehicle.
The reaction to tolerable faults may be, for example, observation and/or recording of the fault, restoration to a known, fault-free, previous state, or calculation of a fault-free, follow-up state with the aid of a model.
Control computers 1 , 2 , 3 work with algorithms for checking or evaluating the current state of the vehicle and the “Drive By Wire” system. In particular, the checking includes test routines for the actuators, the sensory system, and the voltage supply.
A catalog of measures, which defines the reactions to all detectable, initial faults, is stored in each control computer 1 , 2 , 3 . The system of the present invention is configured so that, in the case of a fault that is critical with regard to safety, it is still possible to safely pass over into a safe state. In response to the occurrence of a fatal fault, i.e., a fault endangering the safety of operation, this safe state may only be reachable when, in addition to sending optical and/or acoustic instructions to the driver, the trip is forcibly ended by active intervention such as vehicle deceleration, by slowly and continuously braking.
A routine, which allows controlling computer 1 or 3 to formulate a switchover function for switching over to the two other control computers 2 , 3 or 1 , 2 , may be implemented in the control software. This causes its voter signals to be modified, so that the other control-capable computer ( 1 or 3 ) assumes control. This may be necessary for the mentioned hydraulics test routines, which are performed in every driving pause. The detection of a driving pause and the end of a trip is likewise based on a voter-basis decision and is initiated, in each case, by the controlling computer.
Each control computer may determine its own state, as well as that of the system, from the measured values picked up by the sensors and the above-mentioned model calculations, which, e.g., with regard to the steering, take into account the relationship between the steering-wheel angle and the angle of the wheel as a function of the pressures in the steering-cylinder chambers. If at least two control computers determine that the system performance is deviating from their model expectations, then they may suspend the operation of the currently active, controlling computer and thus force a switchover to the second hydraulic steering circuit, by changing their signals sent to voter-basis discriminator (voter) 4 , 5 .
The configuration and the function of the “Steer By Wire” and “Brake By Wire” subsystems are explained in detail below. The “Steer By Wire” subsystem includes a steering-wheel module and steering hydraulics. In this context, the steering-wheel module includes steering wheel 22 , the steering-torque motor, and three sensors 6 , 7 , 8 , which each detect the steering-wheel angle.
The steering hydraulics of each hydraulic steering circuit is divided into two sections (cf. FIG. 2 ). The first section is used to provide the supply pressure and includes a hydraulic-fluid tank 24 , a filter 25 , a pump 27 driven by an electric motor 26 , a non-return valve 28 , a pump bypass valve (2/2 directional control valve) 29 , a reservoir 30 , and a pressure sensor 31 for measuring the supply pressure.
Pump 27 conveys hydraulic fluid from tank 24 through non-return valve 28 , into reservoir 30 . If a predefined, maximum supply pressure is reached, then pump 27 is limited or shut off, using suitable software. If the supply pressure falls below a predefined, minimum supply pressure, then pump 27 is switched on again. Non-return valve 28 prevents the pressure from falling in the direction of tank 24 . In the open state, pump bypass valve 29 is used to allow pump 27 to start up without counterpressure from the system. The supply pressure built up in reservoir 31 is used for both the steering and the brake. Thus, the line illustrated in FIG. 2 assigned the reference numeral 32 leads to the brake hydraulics, while reference numeral 33 refers to the return line from the brake hydraulics to tank 24 .
The second section of the steering hydraulics includes a double-acting steering cylinder 20 , a proportional valve (3/4 directional control valve) 34 , a steering bypass valve (2/2 directional control valve) 23 , and two pressure sensors 35 , 36 , which are each connected to one of the two cylinder chambers 37 , 38 , respectively, of steering cylinder 20 .
In addition, three sensors 12 , 13 , 14 are present for measuring the wheel angle (cf. FIG. 1 ). In this context, sensors 12 , 13 , 14 measure the angle of wheels 39 , 40 indirectly, by sensing the position of steering-cylinder piston rod 41 , of a tie rod 42 , or of a steering rod.
If steering bypass valve 23 is closed, then a pressure may be selectively built up in each of the two steering-cylinder chambers 37 , 38 , via proportional valve 34 . Piston rod 41 of steering cylinder 20 moves to the left or right as a function of the difference of these two pressures, and thus transmits the steering movement to wheels 39 , 40 . The pressure difference between the two steering-cylinder chambers 37 , 38 forms the basis for calculating the restoring torque generated at steering wheel 22 by the steering-torque motor. Since control computer 2 does not measure the pressure difference itself, this value is transmitted via CAN bus 15 .
The generated restoring torque gives the driver a driving feel, which is dependent on the specific driving situation. Thus, the restoring torque at steering wheel 22 is, for example, markedly less in the case of driving on a smooth, slippery road, than in the case of driving on a relatively rough or dry road. Therefore, it is possible to inform the driver of a looming, critical driving situation in a tactile manner, using the restoring torque generated at steering wheel 22 by the steering-torque motor. Various sensors, in particular pressure sensors, temperature sensors, slip sensors, and/or optical sensors, may be used to detect such situations.
The pressure difference between the two cylinder chambers 37 , 38 is eliminated by opening steering bypass valve 23 . This switches the steering cylinder in question to passive. In this case, the other steering cylinder takes over the adjustment of the wheel angle, while the piston 43 of the passively-switched steering cylinder, which is mechanically connected to tie rod 42 by the piston rod 41 of the other steering cylinder, follows along powerlessly.
The “Brake By Wire” subsystem is made up a brake-pedal mechanism and brake hydraulics (cf. FIGS. 1 and 3 ).
The brake-pedal mechanism simulates the counterpressure of conventional brake hydraulics, using springs. Three springs adjusted to each other press against brake pedal 44 as a function of the position of brake pedal 44 . This gives the driver the usual feel of conventional brake hydraulics.
In each instance, the braking hydraulics (cf. FIG. 3) assigned to one of the two control computers 1 , 3 include: two wheel-brake cylinders, i.e., left front ( 16 ) and right rear ( 116 ), and right front and left rear, respectively; two proportional valves (3/3 directional control valves) 45 , 46 , which are assigned to one of the wheel-brake cylinders 16 , 116 , respectively; a brake bypass valve (2/2 directional control valve) 47 , via which the cylinder chambers of wheel-brake cylinders 16 , 116 may be interconnected; and two pressure sensors 48 , 49 connected to the cylinder chambers of wheel-brake cylinders 16 , 116 , respectively.
In addition, the wheel speeds are detected by two sensors. These sensors are part of an anti-lock braking system and/or a traction control system.
If steering bypass valve 47 is closed, then a different pressure may be built up in each wheel-brake cylinder 16 , 116 , using proportional valve 34 . Pressure sensors 48 , 49 detect these pressures. The separate control of all four wheel-brake cylinders by control computers 1 , 3 allows an anti-lock braking system to be realized.
If, however, brake bypass valve 47 is opened, then the pressure in the two wheel-brake cylinders 16 , 116 is equalized, i.e., the two wheels (front wheel and rear wheel) are equally decelerated. This characteristic is used in test routines to check the two pressure sensors 48 , 49 against supply-pressure sensor 31 (cf. FIG. 2 ), for unacceptable deviations.
The present invention is not limited to the exemplary embodiment illustrated in the Figures. and described above. But rather, a number of variants making use of the inventive idea are possible, even when the arrangement deviates from the present invention. Thus, the system of the present invention may have, for example, an arrangement by which the ratio of the steering-wheel movement to the steering movement of wheels 39 , 40 may be adjusted. The ratio may be varied as a function of the driving situation, e.g., for a parking maneuver or traveling on an expressway.
Furthermore, it is useful to combine the system with an electronic vehicle immobilizer, since the mechanical decoupling of steering wheel 22 and steerable wheels 39 , 40 eliminates the need for a conventional steering-column lock.
List of reference numerals
1 control computer
2 control computer
3 control computer
4 voter-basis discriminator (voter)
5 voter-basis discriminator (voter)
6 sensor for detecting the steering-wheel angle
7 sensor for detecting the steering-wheel angle
8 sensor for detecting the steering-wheel angle
9 sensor for detecting the position of the brake pedal
10 sensor for detecting the position of the brake pedal
11 sensor for detecting the position of the brake pedal
12 sensor for detecting the steering angle, e.g., wheel angle
13 sensor for detecting the wheel angle
14 sensor for detecting the wheel angle
15 can bus
16 front wheel-brake cylinder
17 front wheel-brake cylinder
18 hydraulic control unit
19 hydraulic control unit
20 steering cylinder
21 steering cylinder
22 steering wheel
23 steering bypass valve
24 hydraulic-fluid tank
25 filter
26 electric motor
27 pump
28 non-return valve
29 pump bypass valve
30 reservoir
31 supply-pressure sensor
32 line to the brake hydraulics
33 return line
34 proportional valve
35 pressure sensor
36 pressure sensor
37 steering-cylinder chamber
38 steering-cylinder chamber
39 wheel
40 wheel
41 steering-cylinder piston rod
42 tie rod
43 steering-cylinder piston
44 brake pedal
45 proportional valve
46 proportional valve
47 brake bypass valve
48 pressure sensor
49 pressure sensor
50 reservoir
51 electric motor
52 pump
116 rear wheel-brake cylinder | A “drive by wire” system reverts to a safe condition if an error affecting safely is identified. The system includes a steerable wheel, a steering device, and control computers linked to sensor(s) which detect movement and position of the steering wheel. The system includes positioning devices mechanically coupled to the steerable wheel and controllable by one of the control computers and majority voting units. The positioning unit is actively controllable by its assigned control computer. The control computers determine their own condition and the condition of the system by model-based calculations, using measured values detected by the sensors and switch over from, the currently active control computer to the control computer assigned to the other positioning unit, if deviations from the model forecasts in a majority of the control computers are indicated. | 1 |
BACKGROUND 0F THE INVENTION
The present application is a continuation-in-part application of U.S. application Ser. No. 07/766,781 filed Sep. 27, 1991, now abandoned.
The present invention relates to a collapsible container, and in particular to a disposable collapsible bottle especially suited for carbonated beverages.
Plastic bottles are conventionally used for storing beverages, such as soft drinks and sodas. For stability purposes, known plastic bottles usually either have a cup attached to the base of the bottle, or they stand on molded feet, or pedestals, formed on the base.
Plastic bottles also usually employ removable caps which are effective in sealing the bottle's contents. However, because all of the carbonated beverage in a bottle often is not dispensed at one time, a bottle frequently is resealed with a higher air-to-beverage ratio than before. Consequently, the beverage's carbonation is diminished as a direct result of its escape into the increased volume of air within the bottle. A loss of carbonation leaves the beverage less appetizing to the consumer.
The beverage industry produces plastic bottles in extremely large quantities. Therefore, they must be inexpensive to manufacture and easily stored in a minimum amount of space. Storage space also is a concern for the consumer. Moreover, since containers are marketed to the public in vast quantities, they must be either ecologically disposable or easily recyclable.
A need therefore exists for an improved plastic bottle which satisfies each of these criteria while providing the capability for sustaining a high carbonation level in the beverage.
SUMMARY OF THE INVENTION
The present invention satisfies the foregoing needs. More particularly, the improved collapsible bottle allows a consumer to easily maintain the trapped air volume in a beverage container substantially constant as the bottle is emptied, thereby effectively eliminating the loss of carbonation in the beverage. Furthermore, the bottle may be economically produced and efficiently stored by both the manufacturer and the consumer.
Carbonation depletion significantly impacts the consumer's enjoyment of a beverage. However, carbonation in the beverage can be maintained by controlling the amount of air in the sealed bottle. This can be achieved in various ways. One known way of doing so is through the use of a collapsible bottle. With this technique, the total volume of the bottle is reduced as the beverage is consumed, thereby maintaining substantially constant the amount of air in the container.
A unique feature of the present invention is an improved arrangement for causing a collapsible bottle to be compressed to reduce its volume. This feature is incorporated in respective embodiments of the invention used with the two basic types of plastic beverage containers currently on the market, viz., plastic bottles having a cup secured to the bottom of the bottle and those having molded feet or pedestals on the bottom which keep the bottle upright and stable.
In each embodiment of the invention, a plurality of straps extend lengthwise along the bottle's exterior. The straps are attached to a collar positioned around the neck of the bottle and are secured to a ratcheted winding mechanism at the bottom of the bottle. For bottles with a cup as the base, the rotatable member of the winding mechanism is the cup itself. For pedestal-type bottles, a rotating knob, preferably provided with an easily accessible finger grip, is provided centrally of the pedestals at the bottom of the container. If either the cup or the knob is rotated at a time when pressure within the bottle is relieved, the straps are wound around a stem or spool, thus effectively shortening the length of the straps between the top and bottom of the bottle.
The wall of the central portion of the bottle is pleated in an accordion or bellows-type configuration. Consequently, when the straps are shortened, the bottle collapses and becomes shorter. The consumer rotates the knob or cup until the bottle is short enough to bring the level of the remaining beverage close to the top of the bottle in its neck region. In this way, when the cap reseals the container, the volume of air in the bottle is controlled, whereby the loss of carbonation is substantially reduced.
A further feature of the invention is that the pleats of the central portion of the bottle are dimensioned and configured in such a way as to permit the bottle to smoothly and uniformly collapse as compression forces are exerted on the central portion when the strap lengths are shortened.
In addition to controlling carbonation loss, the present invention is one which can be inexpensively manufactured and is easily usable by a broad range of consumers. Furthermore, in a compressed state, a plastic bottle requires less storage room, and because of its reduced volume, it is more readily ecologically disposed of or recycled.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention now will be described in greater detail with reference to the accompanying drawings wherein:
FIG. 1 is a fragmented side elevational view, partially in section, of a first embodiment of a disposable collapsible bottle according to the present invention;
FIG. 2 is an enlarged view of a portion of the bottle shown in FIG. 1;
FIG. 3 is a fragmented view of a portion of the bottle shown in FIG. 1, the bottle being illustrated in a partially collapsed condition;
FIG. 4 is a fragmented bottom view of a portion of the embodiment shown in FIG. 1;
FIG. 5 is a top plan view of another portion of the embodiment shown in FIG. 1;
FIG. 6 is a sectional view taken along the line 6--6 of FIG. 4;
FIG. 7 is a fragmented side elevational view, partially in section, illustrating further details of the embodiment shown in FIG. 1;
FIG. 8 is a fragmented bottom view of an alternative to the embodiment shown in FIG. 4;
FIG. 9 is a top plan view of an alternative to the embodiment shown in FIG. 5;
FIG. 10 is a side elevational view, partially in section, of a second embodiment of the invention;
FIG. 11 is fragmented bottom view of a portion of the embodiment shown in FIG. 10;
FIG. 12 is a top plan view of the winding knob portion of the embodiment shown in FIG. 10;
FIG. 13 is a fragmented sectional view taken along the line 13--13 of FIG. 11;
FIG. 14 is a top plan view of an alternative to the winding knob portion of the embodiment shown in FIG. 10; and
FIG. 15 is a fragmented sectional view of an alternative to the embodiment shown in FIG. 13.
DETAILED DESCRIPTION OF THE INVENTION
FIG. 1 illustrates a first embodiment of the invention. More particularly, a plastic bottle is shown, the bottle comprising a base portion 10, a top portion 12 and a central portion 14 joining the base and the top.
The base portion 10 comprises a molded bottom surface 16 generally is hemispherical in shape. A plastic cup 17 surrounds surface 16. The underside of cup 17 provides a resting surface for the bottle.
The top portion 12 of the bottle consists of conventional neck and cap sections 18 and 19, respectively.
The central portion 14 joining the base 10 and top 12 is a pleated plastic section integrally joined with portions 10 and 12. For convenience of illustration, only four full peripheral pleats are shown. It will be understood, however, that in practice, additional pleats are contemplated. For example, a bottle of two liter volume typically would include 9-10 peripheral pleats.
Details of the peripheral pleats can be appreciated by reference to FIGS. 2 and 3. More particularly, the pleats are formed by central portion 14 being provided with fold lines spaced substantially equally along its wall. Consequently, the lengths of the walls between adjacent fold lines are uniform. Adjacent fold lines are arranged so that they alternately fold inwardly toward the longitudinal axis of the bottle and outwardly away from the bottle's axis. As a result, portion 14 folds in accordion-like fashion along its periphery.
The outer fold lines 20 have a wall thickness greater than the thickness of the inner fold lines 21. While the outer fold lines 20 define parallel planes which are normal to the longitudinal axis of the bottle, the inner fold lines are folded at radially spaced intervals. The latter folds alternately are in an opposite sense relative to the direction of the bottle's longitudinal axis. As a result, the walls of central portion 14 also are interiorly pleated radially of the longitudinal axis of the bottle. These pleats generally are indicated as 22 in FIG. 3.
As a result of the different wall thicknesses at fold lines 20 and 21, and the provision of radially oriented pleats 22, as the bottle collapses, the folding of the central portion occurs smoothly and uniformly along the length of portion 14 with the interior folds 21 nesting with adjacent folds of corresponding radial orientation. This can be appreciated from the FIG. 3 illustration.
The present invention provides means for permitting the bottle to be collapsed from a fully expanded condition when pressure within the bottle is relieved and force is provided to the bottle longitudinally of its central axis. More particularly, a circular plastic collar 24 rests on the neck 18 of the bottle (FIG. 1). This is be accomplished by passing collar 24 over the cap 19. A plurality of flexible plastic straps 26, integrally formed with the collar 24, and located at radially spaced intervals around the collar, extend downwardly along the surface of the bottle to a ratcheting arrangement 28 at the bottom of the bottle. The arrangement 28 will be described in greater detail hereinafter. However, for present purposes, it is sufficient to describe the arrangement as one in which straps 26 are secured to the ratcheting arrangement in such a manner that when cup 17 is rotated relative to the stationary bottom surface 16, the lower ends of straps 26 are wrapped around a stem or spool, thereby shortening the length of the straps. The consequence of this is that force is applied to the bottle and the central portion 14 is compressed, thereby reducing the bottle's volume.
To prevent the collar 24 from rotating relative to neck 18 during the shortening of straps 26, the neck 18 is provided with a plurality of radially displaced depressions 29 which receive the straps to arrest them against applying forces to the collar which would cause the collar to rotate.
The second embodiment of the invention is shown in FIG. 10. For purposes of description, those portions of the invention shown in FIG. 10 which are common to the FIG. 1 embodiment are identified by the same reference numerals.
The arrangement of FIG. 10 differs from that of FIG. 1 in respect of the base portion. More particularly, rather than utilizing a cup at the bottom of the bottle to provide support, the base portion 30 includes a plurality of pedestals 32 which are formed in the bottom of the bottle as it is molded. Such a pedestal arrangement is well known in the art and need not be described further other than to state that for purposes to be described hereinafter, the number of pedestals preferably is an even number, at least 4.
In conventional bottles of the pedestal type, the pedestals surround a recess at the bottom of the bottle. In the present embodiment, a ratcheting arrangement 34 is provided in the recess. As in the case of the FIG. 1 embodiment, the lower ends of flexible straps 26 are joined to the ratcheting arrangement 34, while the upper ends of the straps are integrally joined to collar 24 resting on the neck 18 of the bottle. Accordingly, when the pressure within the bottle is relieved by opening cap 19, the actuation of the ratcheting arrangement 34 causes the lower ends of the straps 26 to be wrapped around a spool, thereby shortening the straps. This produces a compressive force on the bottle which causes central portion 14 to collapse, thereby reducing the height of the bottle and decreasing the volume of its interior.
From the description just provided with respect to embodiments of FIGS. 1 and 10, it can be appreciated that when the bottle contains a carbonated beverage, the volume of air overriding the upper surface of the beverage within the bottle can be maintained substantially constant as the beverage is dispensed. This is accomplished by the selective actuation of the ratcheting arrangements of the respective bottles. Thus, with the cap 19 secured to the bottle after desired compression is achieved, the loss of carbonation from the beverage is substantially reduced. Additionally, reduction in the size of the bottle facilitates its storage. Also, the compressed bottle can be more easily handled for disposal and recycling purposes, thereby promoting ecological considerations.
Details of the ratcheting arrangements for the two embodiments of the invention just described are illustrated in FIGS. 4-9 and 11-13. More particularly, in FIG. 4, the underside of the bottom surface 16 of the first embodiment of the invention is illustrated.
The bottom of surface 16 is provided with an annular projection 36 which is concentric with the major axis of the bottle. Projection 36 is surrounded by an annular array of inclined segments 38 which also project from the bottom surface 16. The projection 36 and segments 38 preferably are integrally formed with surface 16 during the molding of the bottle.
FIG. 5 illustrates the remaining portion of the ratcheting arrangement 28 of the FIG. 1 embodiment. More particularly, there is provided within cup 17, a centrally located annular member 40 having a central opening 42 dimensioned to receive the projection 36. Member 40 includes radially spaced projections 44 at its periphery, the number of projections corresponding to the number of segments 38 on the underside of surface 16.
Referring to FIGS. 4, 5 and 7, when the cup 17 is positioned on the bottom portion of the bottle, with the projection 36 (FIG. 4) positioned within opening 42 (FIG. 5) of the annular member 40, a portion 46 of the projection 36 serves to position the bottle relative to the cup 17. Portion 46 can be seen in FIG. 6. The lower ends of the straps 26 (FIG. 7) are secured to the annular member 40, whereby when the cup 17 is rotated relative to bottom surface 16, the ends of the strap are wound on member 40. If such relative motion occurs with pressure in the bottle relieved, the projections 44 ride up the inclined surfaces of segments 38. The combined action of the winding of the straps and the rise of the projections on the inclined segments 38 exerts a force on the collapsible central portion 14 of the bottle, causing it to compress. As the projections 44 drop into position between the segments 38, the cup is locked against reverse rotation. Thus, any tendency for the bottle to expand is prevented.
As can be seen in FIGS. 8 and 9, the radially spaced projections 44 and the inclined segments 38 may be located on the bottom of the bottle 16 and the annular member 40, respectively.
If further compression of the bottle is desired, the cap 19 of the bottle remains loosened or removed so as to relieve pressure within the bottle. A manual rotational force on the cup 17 in the direction of the incline of segments 38 causes additional compression of the bottle. When the desired volume of air above the contents of the bottle is achieved, the cap 19 is tightened.
The ratcheting arrangement 34 of the FIG. 10 embodiment is illustrated in FIGS. 11-15. More specifically, the lower ends of straps 26 are connected to a winding knob 48 which includes a disk portion 50 joined to a handle portion 52 by a generally cylindrical spool segment 54 (FIGS. 13 and 15). The top of the winding knob 48 includes a plurality of annular spaced projections 56 formed on the upper surface of disk 50 (FIGS. 12 and 15). The projections 56 cooperate with an annular array of inclined segments 58 (FIGS. 13 and 15) formed on the underside of the bottle 10 concentrically with the bottle's longitudinal axis. The flexible straps 26 extend along the periphery of the bottle, each strap passing between a respective pair of pedestals 32 to be secured at its lower end to the winding knob at its cylindrical portion 54. Consequently, when the handle portion 52 is turned relative to the bottom of the bottle, the straps 26 are wound around spool segment 54 and the projections 56 ride up the inclined surfaces of respective segments 58. As in the case of the FIG. 1 embodiment, when the projections pass over the peaks of the inclined segments 58, they fall into the spaces between the segments, thus locking the handle 52 against reverse rotation. As a result, the bottle is compressed in the manner previously described.
As can be seen in FIGS. 14 and 15, the annular spaced projections 56 and the inclined segments 58 can be located on the bottom of the bottle and the disk portion 50, respectively.
The embodiments which have been disclosed are readily adaptable to conventional plastic bottles. More specifically, the ratchet arrangement 28 in the FIG. 1 embodiment can be formed on the bottom of surface 16 and the interior of cup 17 as those elements are molded. Similarly, the inclined segments 58 of the FIG. 10 embodiment can be produced as the bottle is being molded. The knob portion can be fabricated in a single separate molding operation. The single-piece collar 24 and depending straps 26 also can be easily fabricated, and the lower ends of the straps can be secured to the respective ratcheting arrangements in a simple manner utilizing appropriate slots or openings (not shown) in those portions of the ratcheting arrangements to which the straps are joined.
The present invention has been disclosed with reference to two preferred embodiments which correspond to commercially available beverage bottles. However, other modifications or configurations are possible to those skilled in the art which encompass the scope and spirit of this invention. Furthermore, the present invention has been described with reference to a carbonated beverage, but nothing precludes a non-carbonated beverage from being contained in a bottle according to this invention. | A disposable collapsible beverage bottle is disclosed which includes a plurality of flexible straps extending along the bottle's exterior from a collar surrounding the neck of the bottle to a ratcheting arrangement at the bottom of the bottle. When the ratcheting arrangement is actuated, the straps are shortened causing the bottle to collapse. In this way, the volume of air in the bottle is controlled. | 8 |
BACKGROUND OF THE INVENTION
This invention relates in general to drive train systems for transferring rotational power from a source of rotational power to a rotatably driven device. In particular, this invention relates to an improved method for rotatably balancing a driveshaft adapted for use in such a vehicular drive train system for transferring rotational power from an engine/transmission assembly to an axle assembly.
Drive train systems are widely used for generating power from a source and for transferring such power from the source to a driven mechanism. Frequently, the source generates rotational power, and such rotational power is transferred from the source to a rotatably driven mechanism. For example, in most land vehicles in use is today, an engine/transmission assembly generates rotational power, and such rotational power is transferred from an output shaft of the engine/transmission assembly through a driveshaft assembly to an input shaft of an axle assembly so as to rotatably drive the wheels of the vehicle. To accomplish this, a typical driveshaft assembly includes a hollow cylindrical driveshaft tube having a pair of end fittings, such as a pair of tube yokes, secured to the front and rear ends thereof. The front end fitting forms a portion of a front universal joint that connects the output shaft of the engine/transmission assembly to the front end of the driveshaft tube. Similarly, the rear end fitting forms a portion of a rear universal joint that connects the rear end of the driveshaft tube to the input shaft of the axle assembly. The front and rear universal joints provide a rotational driving connection from the output shaft of the engine/transmission assembly through the driveshaft tube to the input shaft of the axle assembly, while accommodating a limited amount of angular misalignment between the rotational axes of these three shafts.
Ideally, the driveshaft tube would be formed in the shape of a cylinder that is absolutely round, absolutely straight, and has an absolutely uniform wall thickness. Such a perfectly shaped driveshaft tube would be precisely balanced for rotation and, therefore, would not generate any undesirable noise or vibration during use. In actual practice, however, the driveshaft tube and other components of the driveshaft assembly usually contain variations in roundness, straightness, and wall thickness that result in minor imbalances when rotated at high speeds. To prevent such imbalances from generating undesirable noise or vibration when rotated during use, therefore, it is commonplace to counteract such imbalances by securing balance weights to selected portions of the driveshaft tube or other components of the driveshaft assembly. The balance weights are sized and positioned to counterbalance the imbalances of the driveshaft assembly such that it is balanced for rotation during use.
Traditionally, the balancing process has been performed with the use of a conventional balancing machine. A typical balancing machine includes a pair of fittings that are adapted to support the ends of the driveshaft assembly thereon. The balancing machine further includes a motor for rotating the driveshaft assembly at a predetermined speed. As the driveshaft assembly is rotated, the balancing machine senses vibrations that are caused by imbalances in the structure of the driveshaft assembly. The balancing machine is responsive to such vibrations for determining the size and location of one or more balance weights that, if secured to the driveshaft assembly, will minimize these imbalances. The rotation of the driveshaft assembly is then stopped to allow such balance weights to be secured to the outer surface of the driveshaft tube or other components of the driveshaft assembly in a conventional manner, such as by welding, adhesives, and the like. The driveshaft assembly is again rotated to confirm whether proper balance has been achieved or to determine if additional balance weights are required. A number of such balancing machines of this general structure and method of operation are known in the art.
Although such prior art balancing machines have been effective, this balancing process has been found to be relatively slow and inefficient. This is because each driveshaft tube must usually be rotated and measured at least two times, a first time to measure the imbalances and determine the size and location of the balance weights, and a second time to confirm that proper balance has been achieved after the balance weights have been secured thereto. This time consuming process is particularly problematic in the context of balancing vehicular driveshaft tube, which are typically manufactured in relatively large volumes. Additionally, the costs associated with obtaining and maintaining such prior art balancing machines, and to provide the skilled personnel necessary to operate same, are relatively high. Thus, it would be desirable to provide an improved method for quickly and inexpensively balancing an article, such a driveshaft tube for use in a vehicular driveshaft assembly, for rotation about an axis.
SUMMARY OF THE INVENTION
This invention relates to an improved method for quickly and inexpensively balancing an article, such a driveshaft tube for use in a vehicular driveshaft assembly, for rotation about an axis. Initially, a balancing structure is provided that includes a chamber that contains a quantity of a first component of a balancing material. The balancing structure is secured to the article. Then, a quantity of a second component of the balancing material is disposed within the chamber so as to initiate solidification of the balancing material. Lastly, before the balancing material solidifies, the article and the balancing structure are rotated so as to cause the balancing material to move within the chamber to a position wherein the combined assembly of the article and the balancing structure are balanced for rotation. The balancing material solidifies in this position, thus permanently balancing the article for rotation.
Various objects and advantages of this invention will become apparent to those skilled in the art from the following detailed description of the preferred embodiments, when read in light of the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a side elevational view of a vehicle drive train system having a pair of balance structures in accordance with a first embodiment of this invention secured thereto.
FIG. 2 is an enlarged perspective view of a portion of the vehicle drive train system illustrated in FIG. 1 showing a first side of the first embodiment of the balance structure.
FIG. 3 is an enlarged exploded perspective view of the portion of the vehicle drive train system illustrated in FIG. 2 showing a second side of the first embodiment of the balance structure.
FIG. 4 is an enlarged side elevational view, partially in cross section, of the portion of the vehicle drive train system and the first embodiment of the balance structure illustrated in FIGS. 1, 2 , and 3 .
FIG. 5 is a front sectional elevational view of a portion of the vehicle drive train system illustrated in FIG. 1 having a second embodiment of a balance structure in accordance with this invention secured thereto.
FIG. 6 is a sectional elevational view of the portion of the vehicle drive train system and the second embodiment of the balance structure taken along the line 6 — 6 of FIG. 5 .
FIG. 7 is a front sectional elevational view of a portion of the vehicle drive train system illustrated in FIG. 1 having a third embodiment of a balance structure in accordance with this invention secured thereto.
FIG. 8 is a sectional elevational view of the portion of the vehicle drive train system and the third embodiment of the balance structure taken along the line 8 — 8 of FIG. 7 .
FIG. 9 is an enlarged sectional elevational view of a portion of the vehicle drive train system illustrated in FIG. 1 having a fourth embodiment of a balance structure in accordance with this invention secured thereto.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring now to the drawings, there is illustrated in FIG. 1 a drive train system, indicated generally at 10 , for a vehicle that is adapted to transmit rotational power from an engine/transmission assembly 11 to a plurality of driven wheels (not shown). The illustrated drive train system 10 is, for the most part, conventional in the art and is intended merely to illustrate one environment in which this invention may be used. Thus, the scope of this invention is not intended to be limited for use with the specific structure for the vehicle drive train system 10 illustrated in FIG. 1 or to vehicle drive train systems in general. On the contrary, as will become apparent below, this invention may be used in any desired environment for the purposes described below.
The engine/transmission assembly 11 is conventional in the art and includes an externally splined output shaft (not shown) that is connected to a first slip yoke assembly, indicated generally at 12 . The first slip yoke assembly 12 is conventional in the art and includes an internally splined tubular end portion 13 that slidably engages the externally splined output shaft of the engine/transmission assembly 11 . As a result, the tubular end portion 13 of the first slip yoke assembly 12 is rotatably driven by the output shaft of the engine/transmission assembly 11 , but is free to move axially relative thereto to a limited extent. The first slip yoke assembly 12 further includes a yoke portion 14 that forms one part of a first universal joint assembly, indicated generally at 15 . The first universal joint assembly 15 is also conventional in the art and includes a tube yoke 16 that is connected to the yoke portion 14 by a cross in a known manner. The tube yoke 16 is secured, such as by bonding or welding, to a first end of a first driveshaft section 17 for rotation therewith. The first universal joint assembly 15 thus provides a rotational driving connection between the output shaft of the engine/transmission assembly 11 and the first driveshaft section 17 , while permitting a limited amount of angular misalignment therebetween. Alternatively, the output shaft of the engine/transmission assembly 11 may terminate in a conventional end yoke (not shown) which is directly connected to the cross of the first universal joint assembly 15 .
The first driveshaft section 17 can extend through and be supported for rotation by a center bearing assembly, indicated generally at 20 . The center bearing assembly 20 is conventional in the art and includes a rigid frame or bracket 21 that is secured to a support surface, such as a portion of a frame, chassis, or body 22 of the vehicle. The center bearing assembly 20 further includes an annular bearing (not shown) for rotatably supporting the first driveshaft section 17 therein. The first driveshaft section 17 terminates in a second end including an end yoke 23 , which forms one part of a second universal joint assembly, indicated generally at 24 . The second universal joint assembly 24 is also conventional in the art and includes a yoke shaft 25 that is connected to the end yoke 23 by a cross in a known manner. The yoke shaft 25 is, in turn, connected through a second slip yoke assembly, indicated generally at 28 , to a first end of a second driveshaft section 27 . The second universal joint assembly 24 thus provides a rotational driving connection between the first driveshaft section 17 and the second driveshaft section 27 , while permitting a limited amount of angular misalignment therebetween. The structure and operation of the second slip yoke assembly 28 is conventional in the art and forms no part of this invention.
The second driveshaft section 27 terminates in a second end having a tube yoke 30 secured thereto. The tube yoke 30 forms one part of a third universal joint assembly 31 . The third universal joint assembly 31 is also conventional in the art and includes a tube yoke 32 that is connected to an input shaft 33 of an axle assembly 34 by a cross in a conventional manner. The third universal joint assembly 31 thus provides a rotational driving connection between the second driveshaft section 27 and the input shaft 33 of the axle assembly 34 , while permitting a limited amount of axial misalignment therebetween. The axle assembly 34 is conventional in the art and is adapted to transmit rotational power from the input shaft 33 to the driven wheels of the vehicle in a known manner.
As is well known in the art, most driveshaft tubes, such as the driveshaft sections 17 and 27 , usually contain variations in roundness, straightness, and wall thickness that result in minor imbalances when rotated at high speeds. To prevent such imbalances from generating undesirable noise or vibration, first and second balance structures, indicated generally at 40 , are secured to the outer surfaces of the driveshaft sections 17 and 27 . The first and second balance structures 40 are provided to counterbalance the imbalances of the driveshaft sections 17 and 27 such that the drive train system 10 is balanced for rotation during use. The first and second balance structures 40 are preferably identical in structure, although such is not required. As shown in FIG. 1, the first balance structure 40 is secured to the outer surface of the first driveshaft section 17 a predetermined distance inwardly from the first end thereof (i.e., the left end of the first driveshaft section 17 , when viewing FIG. 1 ), while the second balance structure 40 is secured to the outer surface of the second driveshaft section 27 a predetermined distance inwardly from the second end thereof (i.e., the right end of the second driveshaft section 27 , when viewing FIG. 1 ). Preferably, the balance structures 40 are located relatively close (e.g., within about one inch to about one and one-half inches) to the associated ends of the driveshaft sections 17 and 27 to balance the driveshaft section 17 and 27 . Although the illustrated embodiment shows one balance structure 40 secured to each end of the driveshaft sections 17 and 27 , it will be appreciated that additional balance structures can be secured elsewhere to either or both of the driveshaft sections 17 and 27 counterbalance the amount of imbalances therein.
The structure of a first embodiment of one of the balance structures 40 is illustrated in detail in FIGS. 2, 3 , and 4 . As shown therein, the first embodiment of the balance structure 40 includes a mounting bracket including an inner annular bracket portion 42 and one or more outer annular cavity portions 43 positioned adjacent to and radially outwardly from the inner annular bracket portion 42 . In the illustrated embodiment, the mounting bracket of the balance structure 40 is formed from a single piece of metallic material that is pressed or otherwise deformed to the desired shape such that the inner annular bracket portion 42 and the outer annular cavity portion 43 are integrally formed together. However, such is not required, and the mounting bracket of the balance structure 40 may be formed from two or more pieces of material that are joined or otherwise connected together. The mounting bracket of the balance structure 40 may be formed from any desired material or materials.
The inner annular bracket portion 42 of the mounting bracket of the balance structure 40 is adapted to be secured to the driveshaft section 27 . In the illustrated embodiment, the inner annular bracket portion 42 of the mounting bracket is press fit onto the outer surface of the driveshaft section 27 in a desired location. The outer annular cavity portion 43 of the balance structure 40 receives and supports a hollow annular chamber 44 . To accomplish this, the outer annular cavity portion 43 of the illustrated balance structure 40 is defined by an annular wall having a generally C-shaped cross-sectional shape, as best illustrated in FIG. 4, so as to form a captive opening, generally indicated at 43 a , within which the hollow annular chamber 44 may be inserted. The captive opening 43 a resists removal of the hollow annular chamber 44 from the cavity portion 43 of the balance structure 40 . The cavity portion 43 is sized and positioned to support the hollow annular chamber 44 at a predetermined radial distance outwardly from the rotational axis of the driveshaft section 27 . The hollow annular chamber 44 can, for example, be formed from a polymer material that can be cast or molded (e.g., injection molded) to have a desired shape.
The hollow annular chamber 44 is closed so as to retain a quantity of a balancing material 45 therein. The hollow annular chamber 44 can be partially or completely filled with the balancing material 45 , as desired. The balancing material 45 contained within the hollow annular chamber 44 may be embodied as any desired material that is capable of balancing the driveshaft section 27 for rotation. For example, the balancing material 45 may be a composite material that includes a first component and a second component. The first component may be a liquid or fluid material having a quantity of relatively heavy balancing media suspended or otherwise retained therein. The balancing media can, for example, be an alloy of several metallic substances. Preferably, the balancing media is a quantity of powdered metal alloy particles that are suspended in the first component of the liquid or fluid material. Thus, the balancing media is free to move easily throughout the first component of the balancing material 45 contained within the hollow annular chamber 44 . The balancing media adds mass to the balance structure 40 so as to counterbalance the imbalance in the driveshaft section 27 in the manner described below. The specific substance and quantity of balancing media used can be based on the particular application and, therefore, can vary from application to application. A variety of balancing media that can be used, as part of the material 45 is available from the Metals Division of the Mallory Alloys Group, located in the United Kingdom. The second component of the balancing material 45 is adapted to be added to the first component so as to react therewith. For example, the second component of the balancing material 45 can be injected through the wall of the hollow annular chamber 44 into the interior thereof. Alternatively, the second component of the balancing material 45 may be disposed within one or more containers (not shown) provided within the hollow annular chamber 45 . The containers can be broken to release the second component into the first component. Regardless of the specific mechanism by which the second component is added to the first component, the second component of the balancing material 45 causes the first component to solidify, thus retaining the balancing media in a position that counterbalances the imbalance of the driveshaft section 27 .
During a balancing operation, the balance structure 40 is initially secured to the second driveshaft section 27 . During this initial step, the hollow annular chamber 44 contains only the first component of the balancing material 45 . Thus, the first component of the balancing material 45 and the balancing media suspended therein are free to move throughout the hollow annular chamber 44 . The hollow annular chamber 44 is preferably substantially toroidal in shape to promote the flow of the balancing material 45 circumferentially therein. When the second driveshaft section 27 is ready for balancing, the second component of the balancing material 45 is added to the first component, such as in the manner described above. Immediately thereafter, the second driveshaft section 27 is rotated at a desired speed (e.g., just above resonant frequency of vibration). The centrifugal force created by the rotation of the second driveshaft section 27 causes the balancing media contained within the balancing material 45 to be distributed throughout the hollow annular chamber 44 in such a manner that it will counterbalance any imbalance of the second driveshaft section 27 . While the second driveshaft section 27 rotates a chemical reaction occurs between the first and second components of balancing material 45 . Such chemical reaction causes the balancing material 45 contained within the hollow annular chamber 44 to harden, thereby permanently retaining the balancing media in position to balance the second driveshaft section 27 for rotation. If desired, a lattice or other surface irregularity (e.g., serrations, ribs, or the like), such as indicated generally at 44 a , can be provided on the interior surface of the hollow annular chamber 44 . The lattice 44 a can be any shape that resists undesirable movement of the balancing material 45 after it has solidified.
As an alternative to using a chemical reaction to harden the balancing material 45 as discussed above, the balancing material 45 contained within the hollow annular chamber 44 can be composed of a thermosetting or thermoplastic material, such as an epoxy resin, that may or may not contain a balancing media. The hollow annular chamber 44 can be filled, partially filled, or coated with the thermosetting or thermoplastic material 45 . If a thermosetting balancing material 45 is used, the second driveshaft section 27 is rotated at the desired speed to allow the liquid thermosetting balancing material 45 to be distributed throughout the hollow annular chamber 44 to rotational balance the driveshaft section 27 . Then, the thermosetting balancing material 45 can be activated by an external heating source so as to cause the balancing material 45 to solidify. On the other hand, if a thermoplastic balancing material 45 is used, the second driveshaft section 27 is initially heated by the external heating source to liquefy the thermoplastic balancing material 45 . Then, the second driveshaft section 27 is rotated at the predetermined speed to allow the thermoplastic balancing material 45 to be distributed throughout the hollow annular chamber 44 to rotational balance the driveshaft section 27 . Then, the external heating source is removed, allowing the thermoplastic balancing material 45 to solidify.
FIGS. 5 and 6 illustrate a second embodiment of a balance structure, indicated generally at 51 , for rotatably balancing a driveshaft tube, indicated generally at 52 . As shown therein, the balance structure 51 is also adapted to be secured to an outer surface 52 a of the driveshaft tube 52 , such as by press fitting. The second embodiment of the balance structure 51 includes two or more hollow annular cavities 53 that are provided for supporting respective hollow annular chambers 54 therein. Each of the hollow annular cavities 53 can be provided with an opening, indicated generally at 53 a , through which a corresponding one of the hollow annular chambers 54 may be inserted. Each of the hollow annular chambers 54 is preferably retained in a fixed relationship with the corresponding annular cavity 53 by any conventional retaining structure (not shown). The annular cavities 53 are sized and positioned to support the hollow annular chambers 54 at a predetermined radial distance from the rotational axis of the driveshaft tube 52 . The hollow annular chambers 54 are closed to retain a quantity of a balancing material 55 therein, as discussed above. As also discussed above, a lattice 54 a or other irregularity (e.g., serrations, ribs, or the like) can be provided on the interior surface of the hollow annular chamber 54 to aid in retaining the balancing media in the desired location.
FIGS. 7 and 8 illustrate a third embodiment of a balance structure, indicated generally at 56 , for rotatably balancing a driveshaft tube, indicated generally at 57 . As shown therein, the third embodiment of the balance structure 56 is similar to the second embodiment of the balance structure 51 described above, except that the third embodiment of the balance structure 56 is adapted to be secured to an inner surface 57 a of the driveshaft tube 57 , such as by press fitting, for example. As described above, the balance structure 56 includes one or more annular cavities 58 that support respective hollow annular chambers 59 . Each of the hollow annular cavities 58 can be provided with an opening, indicated generally at 58 a , through which a corresponding one of the hollow annular chambers 59 may be inserted. Each of the hollow annular chambers 59 is preferably retained in a fixed relationship with the corresponding annular cavity 58 by any conventional retaining structure (not shown). The annular cavities 58 are sized and positioned to support the hollow annular chambers 59 at a predetermined radial distance from the rotational axis of the driveshaft tube 57 . The hollow annular chambers 59 are closed to retain a quantity of a balancing material 60 therein, as discussed above. As also discussed above, a lattice 59 a or other irregularity (e.g., serrations, ribs, or the like) can be provided on the interior surface of the hollow annular chamber 59 to aid in retaining the balancing media in the desired location.
FIG. 9 illustrates a fourth embodiment of a balance structure, indicated generally at 61 , for rotatably balancing a driveshaft tube, indicated generally at 63 . Unlike the balance structures discussed above, the fourth embodiment of the balance structure 61 lacks a mounting bracket and a cavity for retaining an annular chamber. Rather, one or more hollow annular chambers 62 are secured directly to the driveshaft tube 63 . In the illustrated embodiment, the hollow annular chambers 62 are secured to an inner surface 63 a of the driveshaft tube 63 . However, it will be appreciated that the hollow annular chambers 62 can alternatively be secured to an outer surface 63 b of the driveshaft tube 63 . The hollow annular chambers 62 are closed to retain a quantity of a balancing material 64 therein. The hollow annular chambers 62 can be formed in the manner described above. If desired, the hollow annular chambers 62 can be enclosed in a rubber material or other resilient material 65 , such as a polymer foam. The resilient material 65 is compressible when the hollow annular chambers 62 are secured to the driveshaft tube 63 to produce an interference fit between the hollow annular chambers 62 and the driveshaft tube 63 . The composition of the resilient material 65 is based on surface friction required between the balance structure 61 and the driveshaft tube 63 to secure the balance structure 61 to the driveshaft tube 63 .
In accordance with the provisions of the patent statutes, the principle and mode of operation of this invention have been explained and illustrated in its preferred embodiments. However, it must be understood that this invention may be practiced otherwise than as specifically explained and illustrated without departing from its spirit or scope. | A method is provided for quickly and inexpensively balancing an article, such a driveshaft tube for use in a vehicular driveshaft assembly, for rotation about an axis. Initially, a balancing structure is provided that includes a chamber that contains a quantity of a first component of a balancing material. The balancing structure is secured to the article. Then, a quantity of a second component of the balancing material is disposed within the chamber so as to initiate solidification of the balancing material. Lastly, before the balancing material solidifies, the article and the balancing structure are rotated so as to cause the balancing material to move within the chamber to a position wherein the combined assembly of the article and the balancing structure are balanced for rotation. The balancing material solidifies in this position, thus permanently balancing the article for rotation. | 8 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] The present invention relates to copending U.S. application Ser. No. 08/153,624 entitled Improved Climbing Net, filed in the name of Rexroad et al. on Nov. 17, 1993 and also relates to copending U.S. application Ser. No. 08/414,185 entitled Hollow Braid Net and Method of Making, now, U.S. Pat. No. 5,860,350, filed Mar. 31, 1995 and further relates to copending U.S. application Ser. No. 08/557,851, entitled Net With Flattened Surface Members Connected At Sewn Intersection, now, U.S. Pat. No. 5,752,459, and copending U.S. application Ser. No. 09/193,989 entitled Shrink Net and System, filed Nov. 11, 1998.
BACKGROUND OF THE INVENTION
[0002] Field of the Invention
[0003] The present invention relates to nets, and particularly, to those found in barrier or play environments, and relates more particularly, to shrink netting whereby the mesh of the net is capable of being made taught about a frame through the intermediary of a shrinkable net fiber which has a reduced length once wetted and dried.
[0004] It is often desirable to maintain a net mesh in a taught condition while it is held in place on a structure. For example, in the case of a barrier net used for constraining people from going past a given point, such as on a hazardous ledge or the like, it is desirable to maintain the person against movement beyond a given plane without allowing undesirable play in the netting to occur. Such play can only result in additional exposure to danger which otherwise would not occur if the net had remained taut.
[0005] Also, it is desirable in other environments, such as in a playscape, or the like, to provide a netting station which is firm to the grip and does not cause the net to be unstable when climbed. Additionally, in a playground environment, it is desirable to provide a mesh which is soft to the touch when climbed by children. That is, in the playground environment, although a net is made stable by virtue of its being shrunk taught about a frame such as disclosed in copending U.S. application Ser. No. 09/193,989, entitled, Shrink Net And System, which application being commonly owned by the present inventor, it is still desirable to provide a taught net which can be climbed by a child for example, without shoes and without worry about scratches from gripping an abrasive mesh such that holding of the rails and rungs of the net will not result in abrasion of the person's skin.
[0006] Accordingly, it is an object of the present invention to provide an improved shrinking net whereby the net is capable of being shrunk in size to allow pretensioning of the mesh on the frame yet provides a soft and easy to touch mesh for use by children.
[0007] It is still a further object of the invention to provide a netting of the aforementioned type wherein the tensioning of the net can be effected readily and without complication.
[0008] Other objects and advantages of the invention will become apparent from the appended claims and the following disclosure.
SUMMARY OF THE INVENTION
[0009] The invention resides in a flexible member for netting comprising a sheathing made from a flexible synthetic material and having a hollow internal confine extending therewithin. An elongated core member is located within the internal confine of the sheathing and the core member has a plurality of fibers extending longitudinally along the length thereof. The fibers are of a shrinkable material which when wetted and dried cause the flexible member to decrease in length. Means is provided for causing a corresponding length of the sheathing and the core member to become secured against the movement relative to one another such that upon wetting of the internal core member and subsequently drying, the flexible member and the sheathing are reduced in length.
[0010] In one embodiment, the internal core member takes the form of a flat braided rope and the flat braid rope of the core member is disposed within the internal confine of the sheathing such that the sheathing has a generally rectangular shape as seen in side view and is generally defined by first and second spaced long sides extending parallel to one another and by first and second short sides each connected to and extending generally perpendicularly to the first and second long sides and extending parallel to one another to define therewithin the hollow internal confine. Ideally, the sheathing is a multi-filament material formed from color fast polypropylene. The flexible member may be one of a plurality of such members arranged in a lattice of a plurality of the members disposed substantially coplanar with one another such that the long sides thereof overlap at intersections with one another at predetermined angles and being stitched at the intersections thereof.
[0011] In another embodiment, the internal core is a generally cylindric twisted rope and the flexible member is one of a plurality of such members arranged in a lattice of a plurality of such members disposed substantially coplanar with one another intersecting at predetermined spacings such that one member pierces the sheathing and core and passes through it and the other member pierces the one member sheathing and core of the one member and passes through it a nodal point to effect securement of the core and the sheathing in unity with one another. Preferably, the flexible member sheathing is formed of a multi-filament polypropylene material having a diamond braided configuration.
[0012] In another embodiment, the flexible member comprises a plurality of strains being a composite of elongated materials twisted to form a cord. Each of the cords has a plurality of elongated polyester or multi-filament strands intermixed with one of a plurality of yarns which shrink when wetted and dried. The cords are twisted with one another to create the generally cylindrical cord.
[0013] The invention further resides in a method of supporting a net along a support member comprising the steps of: providing a support member having a generally elongated extent and having a given diameter; providing a plurality of lock fasteners which have a free end which connects to an opposite end to create a variably constraining diameter when pulled tight; providing a net having a border with warp and weft members extending generally perpendicularly thereto to define spaces therebetween; stretching the border along the support member and fastening the border member to the support member using the lock fasteners by wrapping the fastener about the net border and the support member in the spacing and pulling the free end of the fastener through a locking mechanism to lock the fastener in place.
[0014] Ideally, the method may be characterized by providing a net having a border which has a generally rectangular shape defined by first and second spaced apart long sides extending parallel to one another and first and second short sides each connected to and extending generally perpendicular to the first and second long sides and extending parallel to one another and locating the long sides of the border flat against the support member and securing the border to the support member with the lock fasteners.
[0015] The invention further resides in a system for supporting a net along a support member comprising a support member having a generally elongated extent and having a given diameter. A plurality of lock fasteners which have a free end which connects to an opposite end to create a variably constraining diameter when pulled tight. A net having a border with warp and weft members extending generally perpendicularly thereto to define spaces therebetween. The border being stretched along the support member and fastened to the support member using the lock fasteners by wrapping the fasteners about the net border and the support member in the spaces and the free end of the fastener being pulled through a locking mechanism to lock the fastener in place with the border and the support member. Preferably, a rubberized sleeve is disposed about the lock fasteners and the border is clamped about the support element in the region of the rubberized sleeve.
BRIEF DESCRIPTION OF THE DRAWINGS
[0016] [0016]FIGS. 1A and 1B show a braided knotted rope each with an inner braided rope core made of fiber that shrinks; FIG. 1A showing more of the outer sheathing, FIG. 1B showing more of the inner shrinking core and FIG. 1C showing in cutaway the relationship between the inner and outer components.
[0017] [0017]FIG. 2 shows a cross lock sewn connection between two perpendicularly disposed shrink net ropes.
[0018] [0018]FIGS. 3 and 3A show, respectively, a sheathing with a flat braid rope of the type shown in FIG. 2 and a sheathing with a twisted or braided shrink rope.
[0019] [0019]FIG. 4 shows a double pierce connection between two sheathed ropes wherein the inner core is a cylindrical twisted or braided rope;
[0020] [0020]FIG. 5 shows an end view of a twisted rope with shrink rope filaments intertwisted within each of the separate cords which are made of polyester or other soft material.
[0021] [0021]FIG. 6 is a partial fragmentary side elevation view of a connection between a structural number and the border of a knotted net.
[0022] [0022]FIG. 7 is an alternative embodiment of the connection shown in FIG. 6 whereby the net is a knotless mesh.
[0023] [0023]FIGS. 8A & 8B show respectively a fastener used in the connections of FIGS. 6 and 7 shown with a cover strap in FIG. 8A and in FIG. 8B shown without a cover strap.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0024] Referring now to FIGS. 1 A- 1 C, it should be seen that a first embodiment of the invention is disclosed and is illustrated as an elongated member referenced generally by the numerals 2 , 2 ′.
[0025] The elongated member 2 , 2 ′ has a two component construction comprised of an outer sheathing 4 and an inner core 6 . As is disclosed previously, for example, in U.S. Pat. No. 5,860,350, the sheathing 4 is made of a color fast diamond braided multi-filament polypropylene hollow rope which his commercially available and sold by Golf Rope and Cordage Inc. of Mobile, Ala. under Part No. 30822-07-3311A.
[0026] Disposed within the internal hollow confine 8 of the sheathing 4 is the shrink cord 6 . In the embodiment illustrated in FIGS. 1 A- 1 C, the shrink cord 6 takes the form of a braided rope having yarns which are formed from a material which shrink along their elongated extent when wetted and dried. These yarns are sold by Kuraray Co. Ltd. under the trade name KURALON Type-T rope through the Kawashaima Trading Co., Ltd., 1-6-28, KYUTARO-MACHI, CHUO-KU, Osaka, Japan. For more complete description of the properties of the yarns making up the shrink cord 6 , reference is made to copending U.S. application Ser. Nos. 09/193,989, which application is being hereby incorporated by reference into the present case.
[0027] The following is a listing of the properties of the yarns that are sold by Kuraray Co. LTD. under the tradename, Kuralon Type-T rope, through Kawashima Trading Co. as employed by the present invention.
TABLE A Properties of Water Soluble Kuralon Perlohke Yarn In addition to the soluble property in hot water, water soluble Kuralon perlohke yarn has the characteristic of remarkable high shrinkage force in water. 1. Characteristics of water soluble Kuralon perlohke yearn. (1) High shrinkage ratio in wet state. 40% at free tension (2) High shrinkage force in wet state. In case of 10's, the shrinkage force is about 30 gr. When the both ends of yarn are fixed. (3) High elongation at break. (4) At wet state it shows elasticity like rubber. (5) Abrasion resistance at wet state is a little inferior to that of normal Kuralon perlohke yearn. (6) Tensile strength is about half of normal Kuralon perlohke yarn. (7) It dissolves in water at more than 80° C. (8) Standard Properties of Kuralon Yarn. Description 2005P20/1T 2005P10/1T Yarn Count ECC 20'S ECC 10'S Dry Tensile Strength Kg 0.60 1.70 Tenacity g/dr. 2.20 3.01 Elongation % 15.0 17.0 Wet Tensile Strength Kg 0.25 0.49 Tenacity g/dr. 0.92 0.87 Elongation % 102 108
[0028] In addition to the specific characteristics above in Table A, below listed in TABLE B, are further characteristics illustrative of the yarn material used by the present invention.
TABLE B KURALON (PVA) HIGH SHRINKAGE CORD This yarn exhibits the unique behavior of fast shrinkage combined with a high shrinkage force when it becomes wet. 1. Initial Reactive Properties (a) Fast shrinkage: The time required to reach 30% shrinkage is about 7 seconds in water at 20 Deg. C. and about 4 seconds in water at 30 Deg. C. (b) High shrinkage: The shrinkage ratio is about 75% in water at 20 Deg. C. and about 78% in water at 30 Deg. C. (c) High shrinkage force: After absorbing water, a high shrinkage force is readily apparent. The shrinkage force is about 170 gram (0.1 gram/danier) in water at 30 Deg. C. after 10 seconds. 2. Long Term Properties (a) High strength after shrinkage: Strength is about 1 gram per denier after yarn is soaked for 16 hours. (b) Elasticity can be maintained for a long time. 3. Standard Properties Denier: 1786 Unit Length (meter/gram): 5.0 Moisture Content (%): 9.2 Strength (Kg): 3.88 Tenacity (gram/dr): 2.17 Elongation at Break (%): 26.0
[0029] Referring now to FIGS. 1A and 1C, it should be seen that the internal confines 8 of each of the ropes 2 , 2 ′ is sufficiently large to permit the one rope numbered 2 to be pierced through by the other rope numbered 2 ′ through both the outer sheathing 4 and the corresponding portion of the inner core 6 and vice versa to effect the cross-piercing arrangement shown in FIGS. 1A and 1B. It should further be appreciated that in embodiment of FIGS. 1 A- 1 C, both the sheathing 4 and the shrink cord 6 take the form of a braided rope having yarns which are loosely woven so as to allow the other of the ropes 2 , 2 ′ to pierce and pass through them at a common location to effect a cross locking arrangement. For a more complete description of the manner by which such cross locking of ropes 2 and 2 ′ occurs, reference can be had to copending U.S. application Ser. No. 08/153,623 which application is being hereby incorporated by reference.
[0030] Referring now to FIG. 2 and to the cross-shaped construction of the two intersecting flat ropes 1 , 1 ′, it should be seen that each rope is comprised of a sheathing member 4 , 4 ′ identical to that shown in FIGS. 1 A- 1 C, but that the internal shrink cord referenced as 6 ′ in FIG. 2 has a flat tightly braided rope configuration, rather than being loosely braided which permits the sheathing 4 to take on a more compact and tape-like configuration. That is, each of the sheathing members 4 , 4 ′ has two generally parallel disposed long side faces 10 , 10 which extend parallel to the longitudinal axis LA of the rope 1 . Each sheathing member further has two short side faces 12 , 12 which are formed so as to be disposed perpendicularly to the long side faces 10 , 10 such that each rope 1 , 1 ′ has a generally tape-like configuration. This tape-like configuration allows a flattened configuration of the rope members to occur.
[0031] A connection between the two ropes 1 , 1 ′ can be effected by laying one rope flat on top of the other and stitching at the overlap 14 . In the example shown, the stitching 14 occurs through the intermediary of a box stitch made through the overlapped ropes, however, other types of stitches can be used to effect the same type of connection. The box stitch 14 while not only effecting the connection between the intersecting sheathing members 4 , 4 ′, further serves to fix the coaxially disposed core members 6 ′, 6 ′ to the sheathing in unity with one another.
[0032] It should be understood from a review of FIGS. 3 and 3A, that the characteristics of the core 6 ′ can vary without substantially altering the effect of the ropes 1 , 1 ′. That is, the core 6 ′ used in FIGS. 3 and 3A is a flat tightly braided rope in sheathing. However, as shown in FIGS. 3 and 4, the shrink cords 6 ″ as shown therein are formed from the strands of shrink fiber from the material set forth above which are twisted into a cylindrical form rather than being braided to create a cylindrical rope, rather than one that is flattened. As illustrated in FIG. 4, the sheathing 4 being of the type disclosed in FIGS. 1 A- 1 C is pliable and will take on a cylindrical shape of the internalized cylindrical shrink cord 6 ″ inserted therein and thus is piercable at node 5 in manner set forth and discussed above with reference to FIGS. 1A and 1B.
[0033] Referring now to the further embodiment of FIG. 5, it should be seen that a twisted rope 20 which has a polyester or multi-filament polypropylene base material 21 between which are inter-dispersed lengths of shrink rope filaments 6 ′″, 6 ′″. The lengths of the base material 21 and the lengths of shrink filaments are twisted together to form single independent cords 23 a , 23 b and 23 c which are in turn twisted together to form the twisted rope 20 . In this way, once wetted and allowed to dry, the rope 20 will be caused to shrink along its length through the shrinking action of the shrink elements 6 ′″ working in the manner discussed above.
[0034] Referring now to FIGS. 6 - 8 , it should be seen that a system for supporting a net or mesh 26 , 26 ′ with a border is disclosed. The net illustrated in FIG. 6 as element 26 is one such as disclosed in FIG. 20 of U.S. Pat. No. 5,752,459, which is hereby incorporated by reference, or can be a knottless Rachel type net as illustrated in FIG. 7 which has no cross piercing members. In either case, the net 26 , 26 ′ is of the type having a border 28 , 28 ′ which can extend lengthwise in a given direction so as to be stretched in a lengthwise dimension.
[0035] As seen in FIGS. 6 and 7, an elongate structural support element 29 is employed for securing with it a length of the border 28 , 28 ′. In so doing, the border 28 , 28 ′ is stretched along the length of the element 29 and is connected to it in discrete places by means of a plurality of lock fasteners 32 , 32 . The net disclosed in U.S. Pat. No. 5,752,459 is particularly useful in such an application in that it has flat side faces as defined by dimension W which are ideally suited for placement against the opposing surface of the member 29 .
[0036] As is known, weft or warp members 30 , 30 ′ of the mesh 26 , 26 ′ connect to the borders 28 , 28 in a T-like connection so as to cause spacings S,S, therebetween. It is within the spacings that the lock fasteners 32 , 32 connect with the member 29 . The lock fasteners 32 , 32 which are shown in greater detail in FIGS. 8A and 8B.
[0037] As seen in FIGS. 8A and 8B, each of the lock fasteners 32 , 32 is comprised of a generally flat tape-like piece of metal 34 having a tapered free end 36 which is adapted to be received within a one way, pull-out resistant locking mechanism 38 secured to the opposite end of the strip 34 . It has been found that the substantial width of the metallic strip 34 , for example, on the order of about one quarter inch, is effective to cause a desired bearing and clamping surface to be effected between the border 28 , 28 ′ of the mesh 26 , 26 ′ and the structural member 29 as well as between the lock fastener 32 and the member 29 which it contacts. To further enhance this bearing capacity, it is also desirable to use a rubberized bearing sleeve 40 which is disposed about the metallic strip portion for the fastener. The lock fasteners 32 , 32 are readily commercially available and are sold by Panduit Corporation, 17301 Richland Avenue, Tinley Park, Ill. 60477-3091.
[0038] Accordingly, Applicant has disclosed an improvement in shrink net technology which is neither obvious nor novel in order to illustrate the invention. However, numerous modifications and substitutions may be had without departing from the spirit of the invention. For example, with respect to the connection shown in FIGS. 6 and 7, it is well within the purview of the invention to provide the connection shown therein which uses no shrinkable fibers and simply connects a netting to a member as illustrated. | A flexible member used as a rope in a mesh has an outer sheathing which is easy to touch and an inner core which is shrinkable so that when used in a mesh which is suspended on a frame, it pulls the frame tautly by the shrinkage of the inner cords. Also, a connection between a support member and a border can be effected using one way mechanical fasteners. Shrink nets can be further used on a frame without sheathing with a twisted cord. | 3 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims the benefit of U.S. Provisional Application Ser. No. 61/307,749 which was filed on Feb. 24, 2010.
FIELD OF THE INVENTION
[0002] The present invention is generally directed toward a non-tracking, hot applied tack coat for bonding two layers of hot mix asphalt together and its methods of application.
BACKGROUND OF THE INVENTION
[0003] Thin Mix HMA, Bonded Friction Course, and Open Graded Friction Courses (OGFC) (also known as Porous friction Courses, Gap Graded Asphalts, or Stone Matrix Asphalts) have grown in popularity in recent years due to their important advantages over the roadways paved with dense graded hot mix asphalt (HMA) and over concrete pavements. These advantages include a reduced risk of hydroplaning, improved drainage, improved visibility, coarse surface for improved friction values, and reduced noise. However, the disadvantages of OGFC have been well documented and include reduced durability, debonding of the OGFC layer, and stripping in the OGFC and underlying areas.
[0004] The durability issues have been largely addressed by the use of a Bonded Friction Course (BFC) system that employs the use of improved polymerized tack coat materials and processes. One such Bonded Friction Course system, known as the NOVACHIP process and described in U.S. Pat. No. 5,069,578, uses a specialized “Spray Paver” machine to apply a thick layer of polymer modified tack coat immediately before a thin gap-graded HMA layer is applied. This polymer modified tack coat wicks into the new gap graded mix by displacement and water vaporization. The tack coat provides a degree of adhesion or bonding between the layers and also acts to reduce slippage and sliding of the layers relative to other layers in the pavement structure during use or due to wear and weathering of the pavement structure. The thick application of the tack coat further seals minor cracks in the existing surface layer and forms a strong bond between the new HMA layer and the existing pavement.
[0005] However, the NOVACHIP bonded friction course system can be prohibitively expensive due to the requirement that the specialized “Spray Paver” machine be used. Currently, each spray paver machine costs almost $500,000.00, and many contractors and state agencies cannot justify the expense. However, without the use of the NOVACHIP Spray Paver, the thick layer of emulsified polymer modified tack coat used in a bonded friction course system would be very difficult to work with. The thick layer of emulsion tack coat would have a very slow cure rate, resulting in unacceptable delays and also tracking of the tack coat layer. Tracking occurs when the tack or bonding coat is picked up on the tires or tracks of vehicles traveling over the coated surface. Where this occurs, the asphalt compositions often are tracked onto other pavement surfaces causing disruption to the surrounding area. This tracking also reduces the effectiveness of the tack coat by displacing a portion of the intended volume from the area awaiting a new pavement layer.
[0006] Insufficient adhesion between a new layer of pavement and an existing base course, a previously laid pavement layer, or a prepared pavement surface can cause pavement separation and cracking during construction of the structure, as well as subsequent failures and premature deterioration of the pavement structure and/or surface. Such conditions often require costly repairs, can cause damage to vehicles traveling on the surface and may cause dangerous traffic conditions threatening damage to property and injury to vehicles and passengers.
SUMMARY OF THE INVENTION
[0007] We disclose a new system for creating a bonded friction course pavement structure that does not require the use of specialized machinery for its application. The system employs conventional asphalt distributors to place a hot-applied, polymer modified tack coat having the properties after cooling of being non-adhesive at ambient temperatures. The polymer modified tack coat layer is applied while hot, at temperatures greater than 212° F. in a liquid form, and may be allowed to cool to ambient temperatures. At ambient temperatures, the polymer modified tack coat is non-tracking and non-adhesive. However, when it comes into contact with a new hot mix asphalt layer, the polymer modified tack coat becomes adhesive, again. The resulting pavement structure made through use of the claimed methods has improved strength compared to other known paving systems.
BRIEF DESCRIPTION OF THE DRAWINGS
[0008] Further advantages of the invention will become apparent by reference to the detailed description of preferred embodiments when considered in conjunction with the drawings:
[0009] FIG. 1 is a graph comparing the interface strengths of different tack materials.
DETAILED DESCRIPTION
[0010] The following detailed description is presented to enable any person skilled in the art to make and use the invention. For purposes of explanation, specific details are set forth to provide a thorough understanding of the present invention. However, it will be apparent to one skilled in the art that these specific details are not required to practice the invention. Descriptions of specific applications are provided only as representative examples. Various modifications to the preferred embodiments will be readily apparent to one skilled in the art, and the general principles defined herein may be applied to other embodiments and applications without departing from the scope of the invention. The present invention is not intended to be limited to the embodiments shown, but is to be accorded the widest possible scope consistent with the principles and features disclosed herein.
[0011] By using a non-tracking, polymer modified tack coat that is non-adhesive at ambient temperatures, a specialized “Spray Paver,” such as that used in the NOVACHIP bonded friction course system, is no longer required. Instead, conventional distributors and paving equipment can be used. The hot-applied polymer modified tack coat is heated until it is liquid and sprayable and, then, sprayed on the pavement to create the thick layer. Typically this tack coat is applied at the rate of 0.04 to 0.8 gals/yd 2 for a conventional HMA overlay, or 0.09 to 0.18 gals/yd 2 for a Bonded Friction Course. Once applied, the layer of tack coat cures hard to the touch in seconds to form a non-tracking surface. Cracks that may exist in existing pavement are filled by this thick layer, thus sealing the surface. A hot-mix asphalt layer can, then, be placed over the tack coat layer almost instantly after the tack coat layer has cooled.
[0012] As the tack coat cools, it becomes non-adhesive, and, therefore, non-tracking. Vehicles can drive over this layer without fear of the tack coat sticking to the tires of the vehicles. When the hot-mix asphalt layer is applied on top of the tack coat, the heat of the HMA layer causes the tack coat to liquefy, and this liquefied polymer modified membrane is wicked into the HMA layer by displacement. At the higher temperatures of the hot mix layer, the tack coat is extremely adhesive, allowing it to form a strong structural bond with the OGFC or other hot mix asphalt layer. As the polymer modified tack coat cools, the bond with the hot mix asphalt layer becomes stronger. However, the polymer modified tack coat retains its flexibility.
[0013] It should be appreciated that this polymer modified trackless tack coat is particularly useful in Open Graded Friction Course, Bonded Friction Course, and thin overlay mixes where the material was previously applied with specialized distributors, such as “Spray Pavers.” However, using the claimed method only a conventional distributor and paver are required. As a result, the methods disclosed are available to all contractors and government agencies that do not want to purchase a proprietary or specialized machine.
[0014] The disclosed method may use any tack coat formulation that has the desired properties of being adhesive only at higher temperatures, but not at ambient temperatures. The tack coat can be made by blending a low pen asphalt and/or with a polymer. Harder asphalts with low pen values have higher softening points. By reducing the amount of hard pen asphalt in an asphalt composition, and increasing the amount of other ingredients such as polymers, an asphalt composition can be made that has a softening point that is lower than the temperature of hot mix asphalt, but high enough that it is not adhesive when it cools to ambient temperatures. In one embodiment, the non-tracking polymer modified tack coat can be made by producing an asphalt cement having a penetration of 0 to 50 dmm and combining its polymers and additives to achieve a softening point of 135° C. or higher.
[0015] The polymers and additives in the tack coat add strength and flexibility to the tack coat. The polymers and additives are added at various concentrations to an asphalt cement in order to achieve the desired physical properties of the trackless tack. The polymers that can be used in modifying the tack coat include, but are not limited to, SBS, SB, SEBS, XSB, EVA, polypropylene, acrylic polymers, Ground Tire Rubber, natural and synthetic waxes, Gilsonite, Trinidad Lake Asphalt, plastomers, elastomers, hardeners and softeners, or any combination, including oxidizing, thereof known in the art that allows the tack coat to achieve the properties of being non-adhesive at ambient temperatures. For the purposes of this application, ambient temperature is any temperature that is typically used in paving applications. Currently, paving is typically only performed at temperatures greater than 40° F.
EXAMPLES
[0016] The following standard procedures of the American Association of State Highway and Transportation Officials (AASHTO) were used in preparing and testing the pavement compositions. Softening Point (using Ring and Ball Apparatus) was tested as per AASHTO T53. Penetration was tested as per AASHTO T49. Rotational Viscosity was determined as per AASHTO T316. Rheological properties were tested using a Dynamic Shear Rheometer pursuant to AASHTO T315 or PAV(Pressure Aging Vessel) DSR as per AASHTO T315. Flexural Creep Stiffness was tested using Bending Beam Rheometer as per AASHTO T313. Separation of Polymer from Polymer Modified Asphalt was tested as per AASHTO T53 and ASTM D7173.
[0017] In one embodiment, the polymer modified trackless tack has the following properties:
[0000]
TABLE 1
PHYSICAL PROPERTIES
PARAMETER
TEST METHOD
MIN
MAX
Rotational Viscosity @ 135° C., Cp
AASHTO T316
—
3000
Penetration @ 25° C.
ASTM D5
—
50
Softening Point (° C.)
ASTM D36
70
—
Original DSR @ 82° C. (G*/SIN
AASHTO T315
1.0
—
δ, 10 rad/sec)
[0018] In another embodiment, the polymer modified trackless tack is produced by creating a blend consisting of Marathon Hard Pen asphalt with 47% asphalt concentrate of SBS using paddles agitation at 350° F. and 0.5% anti-strip agent, such as Adhere LOF 65-00. The resulting polymer modified tack coat had the following properties:
[0000]
PARAMETER
TEST METHOD
Result
Penetration @ 25° C.
ASTM D5
18 dmm
Softening Point (° F.)
ASTM D36
149° F.
[0019] The softening point is well above ambient temperatures for pavement applications, and, therefore, the resultant polymer modified tack is non-adhesive at ambient temperatures. The tack may then be heated to above 149° F. and applied to a substrate pavement layer, such as a pre-existing pavement at the conventional spray rate of 0.04 to 0.08 gals/yd 2 for a conventional HMA overlay, or 0.09 to 0.18 gals/yd 2 for a Bonded Friction Course. The hot tack coat will bond with the substrate layer and cool to a hard surface that is non-adhesive. A hot mix asphalt layer is then applied to the pavement layer. The heat from the hot mix asphalt is significantly higher than the softening point of the tack coat, causing it to liquefy and be wicked into the hot mix asphalt where it can form a strong bond as the asphalt cools below the softening point of the tack.
[0020] Tests show that the use of the disclosed polymer modified hot tack results in a significantly increased interfacial bond strength between the pavement layers, compared to regular tack methods and materials. As previously discussed, separation of layers will cause premature failure of the roadway, possibly resulting in damage to vehicles or even death. In one test by the National Center for Asphalt Technology, nine slabs consisting of two inches of 12.5 mm open-graded friction course overlaid on two inches of 12.5 mm dense-graded asphalt were prepared and tested. The three tacks tested included the hot applied polymer modified tack as disclosed herein (also referred to as Ultrabond at the time of testing); CQS-1HP, a generic form of NOVABOND tack used by the Alabama Department of Transportation; and NTSS-1HM, a trackless tack made by
[0021] Blacklidge Emulsions, Inc. (Gulfport, Miss.) which is also the subject of U.S. Pat. No. 7,503,724. Six 6-inch specimens were cored from each slab. Two specimens from each slab were cut in half to evaluate the extent of tack coat migration into the OGFC layer. The remaining four specimens were evaluated for bond strength.
[0000]
TABLE 3
Testing specifications:
Spray
Residual
Application
Application
Number
Number
Cores for
Cores for
Rate
Rate
of Slabs
of
Migration
Bond Strength
Tack
(gal/yd 2 )
(gal/yd 2 )
Prepared
Cores
Investigation
Testing
Hot Applied
0.080
0.080
1
6
2
4
Polymer
Modified Tack
Hot Applied
0.130
0.130
1
6
2
4
Polymer
Modified Tack
Hot Applied
0.180
0.180
1
6
2
4
Polymer
Modified Tack
CQS-1HP
0.130
0.080
1
6
2
4
CQS-1HP
0.215
0.130
1
6
2
4
CQS-1HP
0.300
0.180
1
6
2
4
NTSS-1HM
0.160
0.080
1
6
2
4
NTSS-1HM
0.260
0.130
1
6
2
4
NTSS-1HM
0.360
0.180
1
6
2
4
Total
9
54
18
36
[0022] Test specimens were conditioned in an environmental chamber at 77° F. (25° C.) for a minimum of two hours prior to testing. The specimens were, then, loaded into a bond strength device, with the marked layer interface centered between the edge of the shearing block and the edge of the reaction head. Only the shearing block was allowed to move, and the reaction block was stationary. The specimen and the bond strength device were placed in the Geotest S5840 test apparatus with the loading head on top of the bonded interface. The loading apparatus applied a vertical shear load in a controlled displacement mode (0.1 inches/minute) to determine the maximum shear load and maximum displacement of the interface. For each test specimen, the interface bond strength was calculated by dividing the maximum shear load by the cross-sectional area of the specimen.
[0023] FIG. 1 compares the average interfacial bond strengths of the three tack coat materials at three application rates. It should be appreciated that interfacial bond of the presently disclosed tack coat was significantly higher than either of the two prior art tacks. Furthermore, the cores in which the CQS-1HP and NTSS-1HM tack coat materials were used broke cleanly at the interface, indicating that it was the weakest junction between the pavement layers. However, in the cores in which the presently disclosed hot-applied tack material was used, they sheared through the OGFC layer instead of the interface, presumably due to the interface shear strength exceeding the shear strength of the OGFC mix.
[0024] The interfacial strength that results from using the disclosed invention is impressive. It suggests, as it indicates, that a road made according to the methods herein would result in a lower chance of failure. Not only will this increase the life of the paved surface, but it could result in decreased damage to vehicles or their passengers due to OGFC that separates from the substrate layers. Therefore, not only does the invention provide significant benefit due to its non-tracking properties at ambient temperatures and the removal of the need for specialized paving machinery, it also creates stronger and safer pavement structures.
[0025] The terms “comprising,” “including,” and “having,” as used in the claims and specification herein, shall be considered as indicating an open group that may include other elements not specified. The terms “a,” “an,” and the singular forms of words shall be taken to include the plural form of the same words, such that the terms mean that one or more of something is provided. The term “one” or “single” may be used to indicate that one and only one of something is intended. Similarly, other specific integer values, such as “two,” may be used when a specific number of things is intended. The terms “preferably,” “preferred,” “prefer,” “optionally,” “may,” and similar terms are used to indicate that an item, condition or step being referred to is an optional (not required) feature of the invention.
[0026] The invention has been described with reference to various specific and preferred embodiments and techniques. However, it should be understood that many variations and modifications may be made while remaining within the spirit and scope of the invention. It will be apparent to one of ordinary skill in the art that methods, devices, device elements, materials, procedures and techniques other than those specifically described herein can be applied to the practice of the invention as broadly disclosed herein without resort to undue experimentation. All art-known functional equivalents of methods, devices, device elements, materials, procedures and techniques described herein are intended to be encompassed by this invention. Accordingly, the scope of the invention should be limited only by the attached claims. Whenever a range is disclosed, all subranges and individual values are intended to be encompassed. This invention is not to be limited by the embodiments disclosed, including any shown in the drawings or exemplified in the specification, which are given by way of example and not of limitation.
[0027] All references throughout this application, for example patent documents including issued or granted patents or equivalents, patent application publications, and non-patent literature documents or other source material, are hereby incorporated by reference herein in their entireties, as though individually incorporated by reference, to the extent each reference is at least partially not inconsistent with the disclosure in the present application (for example, a reference that is partially inconsistent is incorporated by reference except for the partially inconsistent portion of the reference). | A method of applying building a pavement structure using a polymer modified hot-applied tack coat is disclosed. This polymer modified tack coat is non-adhesive at ambient temperatures, and, thus, also non tracking. The tack is applied while hot, but cools quickly. The subsequent application of hot mix asphalt results in a superior bond between the asphalt layer and the tack layer. It is particularly well suited to bonded friction course applications since it removes the necessity of specialized spray paving machinery and allows the use of conventional asphalt distributors and pavers. | 2 |
CLAIM OF PRIORITY
[0001] The present application claims the priority benefit under 35 U.S.C. §119 to U.S. provisional patent application No. 62/188,935, filed Jul. 6, 2015, entitled METHOD OF ABLATING AND PRINTING ON FIREARMS AND THE RESULTING PRODUCT, the entirety of which is incorporated herein by reference.
BACKGROUND OF THE INVENTION
[0002] The present invention relates to methods of ablating and printing on a metallic surface of firearms, including pistols, revolvers, shotguns, rifles, black powder firearms, and other firearms.
[0003] Firearms can include wood and/or polymeric surfaces that can include engravings and/or color. Firearms also include metal parts that are large enough to receive an image. For example, metal parts of some firearms can be engraved with the trademark or logo of the firearm manufacturer. However, this engraving is typically rough, deep, and does not include any color. To the extent that color, lettering, logos, or other material are simply added to the surface of a firearm, such coloring can be worn off by use or cleaning of the firearm.
[0004] Many firearms are heirloom items that are passed from generation to generation and/or given as gifts. Given the aforementioned limitations of engraving and/or adding color to the metal parts of firearms, little post-sale customization of firearms has occurred.
[0005] Thus, a method for ablating and printing on metallic surfaces of firearms is described herein.
SUMMARY OF THE INVENTION
[0006] One aspect of the present invention is a method for customizing metallic parts of firearms with an image, including a portrait, background scene, lettering, etc., in color.
[0007] Another aspect of the present invention is to provide a customized firearm with a long-lasting, color image on a metallic part of the firearm that is not susceptible to fading and/or wear during repeated use and cleaning of the firearm.
[0008] Another aspect of the present invention is to provide a method for customizing a firearm with a combination of one or more of the following features: a laser ablated surface, ink-printed image.
[0009] Yet another aspect of the present invention is a customized surface of a firearm, with a laser ablated portion of a metal surface of the firearm having a printed ink image within the boundaries of said laser ablated portion of said metal surface of said firearm.
[0010] Still another aspect of the invention is a method for customizing the surface of a firearm. A metal portion of the firearm is selected for an image and then laser ablated. The image is printed on the laser ablated portion of the firearm.
[0011] Yet another aspect of the invention is a fixture for use in the customization of the surface of a firearm. The fixture has a generally flat surface sized to receive a portion of a firearm and to fit under the heads of a laser ablation machine and/or an ink printer. The fixture has at least one adjustable support leg, an adjustment member for moving the generally flat surface along one axis, an adjustment member for moving the generally flat surface along another axis, and a level member for confirming that the generally flat surface is level when it is under the heads of the laser/or and ink printer.
[0012] These and other advantages of the invention will be further understood and appreciated by those skilled in the art by reference to the following written description, claims, and dependent drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0013] FIG. 1 is a perspective view of a surface having a photo jig and firearm part embodying certain aspects of the present invention;
[0014] FIG. 2 is a perspective view of the photo jig shown in FIG. 1 ;
[0015] FIG. 3 is a perspective view of the photo jig shown in FIGS. 1 and 2 , including a firearm part positioned beneath the camera;
[0016] FIG. 4 is a perspective view of a fixture used for positioning the firearm part;
[0017] FIG. 5 is a perspective view of the firearm part positioned on the fixture shown in FIG. 4 ;
[0018] FIG. 6 is a top view of the firearm part with the image dimensions shown in dashed lines;
[0019] FIG. 7 is a top view of a template with the size of the image cut out of the template;
[0020] FIG. 8 is a perspective view of a fixture the holds the template shown in FIG. 7 ;
[0021] FIG. 9 is a perspective view of the fixture shown in FIG. 8 placed over an adjustment fixture holding the firearm part;
[0022] FIG. 10 is a perspective view of the adjustment fixture shown in FIG. 9 holding the firearm part with a mask;
[0023] FIG. 11 is a perspective view of a laser platen for positioning the adjustment fixture under the laser ablation machine;
[0024] FIG. 12 is an image of the adjustment fixture shown in FIGS. 9 and 10 with the firearm part being placed beneath a laser ablating machine; and
[0025] FIG. 13 is a perspective view of the adjustment a fixture as it is placed inside an inkjet printer.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0026] For purposes of description herein, the terms “upper,” “lower,” “right,” “left,” “rear,” “front,” “vertical,” “horizontal,” and derivatives thereof shall relate to the invention as oriented in the attached drawings. However, it is to be understood that the invention may assume various alternative orientations and step sequences, except where expressly specified to the contrary. It is also to be understood that the specific devices and processes illustrated in the attached drawings, and described in the following specification, are simply exemplary embodiments of the inventive concepts defined in the appended claims. Hence, specific dimensions and other physical characteristics relating to the embodiments disclosed herein are not to be considered as limiting, unless the claims expressly state otherwise.
[0027] The reference numeral 2 generally designates a firearm part. The firearm part 2 is customized with an ink image that is placed on a correspondingly sized surface that has been laser ablated on the surface of the firearm part 2 and ink printed in accordance with the present invention. As shown in FIG. 1 , a photograph of the firearm part 2 is taken. The photograph can be reduced in size, such as in an aspect ratio (which provides a proportion relationship between its width, its length, and its height). In addition, a computer program, such as CoreIDRAW X5 or similar software program, can be used to process the image taken with a camera 4 . The camera 4 can be any camera, including a digital camera or the like. Other imaging software and cameras can be used by a person of ordinary skill in the art to achieve similar results.
[0028] As illustrated in FIGS. 2 and 3 , the firearm part 2 is leveled using a level 27 on a photo jig 6 . The photo jig 6 includes a camera stand 16 with a vertical portion 18 , a horizontal portion 20 , and a camera mount 24 . In addition, the camera stand 16 can include adjustment screws 22 that can adjust the vertical and/or horizontal positioning of the camera 4 . Ideally, the camera 4 is positioned above the center of the bullseye 12 on the pad 8 of the photo jig 6 . The photo jig 6 can be positioned on a surface 7 and leveled using a bubble level 27 or the like.
[0029] The leveling of the firearm part 2 on the photo jig 6 can be accomplished by any conventional means, including the utilization of wedges 28 . In addition, to achieve the appropriate aspect ratio, coordinate lines 10 on the photo jig base 8 can be aligned with the firearm part 2 . The camera 4 is raised until the distance between the bottom of the lens of the camera and the top of the firearm part 2 are approximately 17.8125″. A 17.8125″ premeasured stick 26 may be used to position the camera 4 . While this distance is used in the illustrated embodiment, other distances may be used provided that the photograph is clear. The bullseye 12 can assist in focusing the camera 4 . A US quarter 14 (0.955″ diameter) or similarly sized object may also be placed in the image to give a reference dimension on the photo. After the camera 4 is set at the correct distance from the firearm part 2 , the camera 4 and base 8 can be leveled, resulting in the bottom of the camera lens and the top of the firearm part 2 being generally parallel. The picture is made as straight as possible by attempting to align the bottom line of the camera 4 such that it is parallel to the horizontal lines on the photo jig base 8 . Once the camera 4 is set, the image is taken.
[0030] The digital image is then transferred to a computer using a USB drive, micro SD card, or other similar apparatus. The image photo is imported into a software program, such as CoreIDRAW or similar program. The firearm part 2 should remain straight, using a horizontal guideline or similar function in the software program. The photo percentage is then reduced under a scale factor, making sure that the features of the program result in the photo reduction being proportionate. While a 37.2% reduction may be used as a general approximation, the reduction is done to the point where the image looks good. Several points on the firearm part 2 are measured using a ruler, such as the injection port height and width, the rivet and screw locations, etc. The software program is used to create an outline of the exact edge of the firearm part 2 , with the end goal being between the straight lines and curves to create a perfectly outlined firearm part 2 . The position of other elements of the firearm part 2 , such as rivet heads and markings (such as serial number, manufacturer information, etc.), can be noted to potentially exclude those elements from the sizing of the image 62 . A border amount is then determined, which can be uniform all the way around the firearm part 2 or can be un-uniform. In addition, the border can include rounded parts and can adjust around rivet heads, serial numbers, and anything should be excluded from the ultimately ablated and printed design. Once all the dimensions are accurate and the aspect ratio is correct, the image is saved for later retrieval.
[0031] An actual sized template 60 is created. The actual sized template 60 can be made on a transparent vellum or similar material. The size of the image 62 to be placed on the firearm part 2 ( FIG. 6 ) is cut from the template 60 leaving an aperture 63 , as shown in FIG. 7 . A computer program, such as CoreIDRAW X5 or the like, can be used to show what image should be cut from template 60 . A laser, such as a TROTEC C02 laser, can be used to cut the template 60 .
[0032] Prior to the laser ablation step, the template 60 can be placed on a stand 66 , as shown in FIG. 8 . This stand has legs 68 and a surface 70 . The template 60 , with aperture 63 , is taped 72 to the surface 70 of the stand 66 . The stand 66 can then be placed over the adjustment fixture 30 ( FIG. 9 ) prior to the laser ablation step to ensure that the laser ablation machine 84 and the associated laser 86 are properly aligned with the required dimensions for the image to be placed on the firearm part 2 . This optional sequence allows the image to be superimposed on the actual firearm part 2 before ablation. This template 60 and stand 66 can also be used to test the appropriate alignment before the ink printing step. Changes can be made to the template 60 by modifying the dimensions and re-cutting the template 60 .
[0033] The final art for the laser ablation step and the color printing step can be created using a software program, such as Adobe Photoshop or other imaging software, to process the image. The artwork is placed on the area of the shape prepared for the template 60 . Multiple pictures, text, artwork, etc., can be used or bundled together to create the final artwork image. The functions of the software program can be used to blend, edit, contrast, or otherwise tailor the artwork. The artwork is then sized such that it fits within the dimensions of the template 60 created above. The image should be sized such that its dimensions are the same size or slightly larger than the dimensions of the aperture 64 in template 60 than what was created. Thus, the final art image is manipulated so that it aligns exactly with the actual firearm part 2 . The final art image and the firearm part 2 should be superimposed with a generally identical aspect ratio.
[0034] The firearm part 2 is then ready for the laser ablation step. A computer cut file is created on the laser ablation machine 84 , the cut file is aligned with the firearm part 2 . The laser cuts the paint mask 96 ( FIGS. 10 and 12 ) and then ablates the firearm part 2 . Any laser can be used, such as a fiber laser or the like.
[0035] The adjustment fixture 30 and firearm part 2 are mounted on the laser platen 74 and a vacuum can be turned on and attached via a vacuum tube 38 . As shown in FIG. 4 , the adjustment fixture 30 includes an upper plate 32 , a lower plate 34 , an aperture 36 , a vacuum tube 38 , and one or more stands. In the illustrated embodiment, there are two stands 40 , 42 , one of which is adjustable via a lever 43 . The other stand 40 can also be adjustable. The adjustment fixture 30 can include a level bubble 44 . The adjustment fixture 30 can also be placed on a generally flat base 46 , as shown in FIG. 5 .
[0036] The adjustment fixture 30 also includes mechanisms for adjusting the fixture 30 along different axes. For example, one axis adjustment member 48 can include a threaded member 50 for adjustment along one axis, while the other adjustment member 52 includes a threaded member 54 for adjustment along another axis, as shown in FIGS. 9 and 10 and by the arrows in FIG. 12 . These adjustment members 48 , 52 can be below a surface 55 of supporting stands 40 , 42 . In addition, adjustment mechanisms can also be located below the laser platen 74 . For example, one axis adjustment member 76 can include a threaded member 78 for adjusting one axis, while the other adjustment member 80 includes a threaded member 82 for adjustment along another axis, as shown by the arrows in FIG. 12 .
[0037] The adjustment fixture 30 is adjusted and leveled prior to the laser ablation step, as shown in FIG. 12 . The adjustment fixture 30 may be placed onto a laser platen 74 and held in place with pins 75 , as shown in FIGS. 11 and 12 .
[0038] The paint mask 96 is placed on the firearm part 2 , as shown in FIG. 10 (showing the opening 97 that ultimately is cut during the laser ablation process). The surface of the firearm part 2 can be prepared with a cleaning preparation and/or mechanical object, such as a microfiber cloth. The paint mask 96 is applied to the surface of the firearm part 2 , with the mask 96 being pushed down around all rivets close to the cutting area. A laser pointer can be used to outline the rivets or holes to make sure the firearm part 2 is in the correct location. Thus, the measurements are verified and the paint mask 96 is ready to be laser cut. The portion of the mask 96 that is laser cut is then peeled away, as shown in FIGS. 10 and 12 . The firearm part 2 is then laser ablated. The number of passes and the direction and depth of the passes can vary, depending upon the laser ablation machine 84 that is used. The goal is to laser ablate the surface in multiple directions to create a textured ablated surface. The surface of the firearm part 2 can then again be cleaned with a cleaning preparation and/or mechanical apparatus, such as a microfiber cloth.
[0039] Finally, the final art is printed on the ablated surface of the firearm part 2 . Any inkjet printer, such as an Mimaki UV Printer, can be used. The firearm part 2 is installed in a fixture on the bed of the printer. The same adjustment fixture 30 can be used for the ink printing step. The firearm part 2 can again be cleaned with a preparation solution and/or mechanical cleaner, such as a microfiber cloth. The firearm part 2 is then put within the housing 92 of the printer 90 . The artwork is then installed in the software of the inkjet printer 90 . The software program for the laser printer 90 is used to verify that the size of the artwork generally matches the laser ablated surface 88 . Ideally, the laser ablated surface 88 is slightly smaller than the artwork to allow for some tolerance in the printing with a small portion of the artwork being printed on the mask 96 . Software is used to make sure that the pixilation, clarity, and position of the inkjet image is correct.
[0040] A primer layer may be printed onto the laser ablated surface 88 before printing the image. Alternatively, the primer layer can be applied before the firearm part 2 prior to being put into the inkjet printer 90 . If the primer is being printed by the printer 90 , the user can make sure the primer was centered on the ablated surface 80 . If it is not, adjustments can be made. The template 60 may also be used to align the head 94 of the inkjet printer 90 prior to printing. The mask 96 remains on the firearm part 2 during the ink printing step. The artwork is then printed onto the laser ablated surface 88 .
Example 1
[0041] The following illustrated example is simply one example of how the process can be accomplished.
[0042] Phase 1: Take Photo with Photo Jig of Firearm Part.
[0043] (1) Level firearm part on photo jig utilizing wedges and bullseye. Make sure coordinate lines on photo jig base are straight with firearm part.
[0044] (2) Be sure to protect the firearm part by placing a pad between the photo jig and firearm part. Make sure pad does not hide the coordinate lines on the photo jig base.
[0045] (3) With camera on, raise the camera until the distance between the bottom of the lens and the top of the firearm part are 17.8125″. Use the 17.8125″ pre-measured stick to accomplish this. The distance of 17.8125 at this point has the clearest most accurate image.
[0046] (4) Place a US Quarter (0.955″ diameter) on the firearm part. Make sure it is not placed over any rivet holes or the firearm part outline. This will give a reference dimension on the photo.
[0047] (5) After setting camera the correct distance from the firearm part (17.8125″), level camera using the bullseye. Now the bottom of the camera lens and the top of the firearm part should be parallel.
[0048] (6) Make sure picture is straight as possible. This is accomplished by making sure the bottom line of the camera, looking at through the lens, is parallel to the horizontal bottom lines of the photo jig base.
[0049] (7) Once camera is set, take the picture.
[0050] (8) Plug the camera into the computer using the USB.
[0051] (9) Access the newly created firearm part photo and save it for later retrieval.
[0052] (10) Import the firearm part photo into CoreIDRAW—Go to File>New>File>Import>Select firearm photo and press Enter (bottom right hand corner).
[0053] (11) Verify the firearm part is straight using a Horizontal Guideline:
(a) Rotate photo 180°; (b) Drag a guideline down from the top ruler to a straight edge of the firearm part; and (c) Change the Angle of Rotation until straight with the guideline (found on toolbar above).
[0057] (12) Reduce Photo Percentage under the Scale Factor—Start with 37.2%.
[0058] (13) Create rectangles, squares, circles and lines in CoreIDRAW to match the measured dimensions. On the actual firearm part measure several points using a precision ruler. Examples could be: US Quarter (0.955″ diameter); overall width; overall height; ejection port height and width; rivet and screw locations and distance between them. Change the color of the boxes and circles etc. to red or yellow for better contrast so it can be seen. Use the Zoom Tool to be able to see better to superimpose the shapes.
[0059] (14) Once all dimensions are accurate and the “aspect ratio” is correct, save the photo of firearm part for later retrieval.
[0060] (15) For this embodiment we have elected to save as MASTER.cdr file. Make sure file type is .cdr.
[0061] (16) PHASE 1 is now complete.
[0062] PHASE 2: Creating an “Actual Size” Template with Crosshairs on a Transparent Vellum from the Final Art Created in PHASE 1.
[0063] (1) Open the file MASTER.cdr that was saved in PHASE 1. In CoreIDRAW go to File>Open and press Enter.
[0064] (2) Create Outline of the “exact edge” of the firearm part utilizing these steps:
(a) Draw a box and convert to curves:
(i) Draw a box on the firearm part by using the Rectangle Tool (F6) (on the left side); and (ii) Convert to curves—under the Arrange Tab>Convert to Curves or (CTRL+Q);
(b) Use the Shape Tool (F10) on the left hand side to move nodes and create straight lines and curves:
(i) To create a node, Right Click>Add or Double Click the desired location on the outline of the box. (ii) Use straight lines whenever possible. (iii) To make curves—Right Click between two nodes and move line to final location.
(c) Add circles where needed for alignment and art work design (i.e., rivet heads) using the Ellipse Tool (F7) draw rivet heads to size; (d) Bring outline of firearm part in by ⅛″ all the way around by using the Contour Offset Tool on the left side bar:
(i) Go to Blend Tool>Contour Tool. (ii) On the top toolbar change Contour Offset to 0.125″. (iii) With newly created outline selected, click the Inside Contour icon. This will bring the outline in by ⅛″ all the way around. (iv) Break contour group apart—under the Arrange Tab>Break Contour Group Apart or click (CTRL+K). (v) Round squared corners—zoom into corners making new nodes and round corners where needed. (vi) Click the SAVE button.
[0080] (3) Now that the outline is perfect, it is time to create the center point crosshair:
(a) Create a horizontal line—using the Freehand Tool (F5), click once to start line and hold CTRL while dragging and click to make the line. (b) Make a copy of the line—while highlighting the newly created line, click (CTRL+C) and (CTRL+V). (c) Select the newly created line and rotate it 90° on the top toolbar. (d) Using the Pick Tool select both lines by holding Shift and group them together (CTRL+G). The intersecting lines now become one object:
(i) Move the newly created crosshair inside the outline—Click the crosshairs and hold Shift and click the outline. (ii) To center the crosshairs within the outline—go to Arrange Tab>Align and Distribute>Align and Distribute. This brings up the Align and Distribute dialog box. (iii) In the Align and Distribute dialog box, choose Center Vertical and Center Horizontal and click Apply then Close. The crosshairs are now perfectly centered in the outline.
[0088] (4) Once the outline, circles and crosshair of the firearm part are created, it is time to engrave the image on a transparent vellum. This provides an opportunity to view it superimposed on the actual firearm part and make changes where needed. If changes need to be made to the transparent vellum, simply modify the dimensions and re-engrave the vellum until the desired Outline is achieved:
(a) Select all the created outlines, circles etc. and drag a copy to a new page and make a copy by Right clicking while still holding the Left Button on the mouse. (b) Delete what is not needed, leaving only the outlines, rivet holes, and crosshairs. Make the outline RED and Hairline thickness. This is considered the MASTER file. (c) Save the MASTER file to the desired location before the file is saved to the USB Drive to bring to the TROTEC to laser. (d) Open the .CDR file on the TROTEC computer:
(i) Print the file in CoreIDRAW so it sends a file to the TROTEC JobControl Software. (ii) File>Print (or printer icon)>Preferences>Change Size Settings to Page Size (8.5×11)>Material Setting to Clear Transparency>Process Mode (Standard)>Process Option (Resolution—500 DPI)>OK>Apply>Print. (iii) Put clear transparency in TROTEC Bed>Focus using the Silver Aluminum Focus Tool>close the laser lid. (iv) In JobManager double click the previously printed job, this puts the file into the active field>click once on the job to turn it black>click the play button (laser will start).
(e) Test clear transparency on firearm part to superimpose it to make sure everything was created correctly. If tweaks are made re-engrave until everything is created correctly. (f) Make a second copy of MASTER file below and delete crosshairs and outer line leaving rivet holes and inside line ONLY, this is creating a RIVETS & OUTLINE file. (g) Make a third copy from the previously created Outline w/Rivet Holes Only file and delete the rivet holes leaving ONLY the outline, this is called the OUTLINE file. (h) Make a fourth copy from the previously created Outline file and fill it yellow and turn off the outline by right clicking on Clear (in the top box in the color chart); this is creating the FILLED OUTLINE file.
[0101] (5) Export two EPS files for the Artwork Design that will be used in PHASE 3. Choose a location that can be easily retrieved for PHASE 3:
(a) Select the RIVETS & OUTLINE file using the Pick Tool and Export>RIVETS & OUTLINE.eps. Go to File>Export (CTRL+E)>Make Sure File Type is .eps>Selected Only is Checked>RIVETS & OUTLINE>Export>Verify EPS Dialog box>OK. (b) Select the FILLED OUTLINE file using the Pick Tool and Export>FILLED OUTLINE.eps. Go to File>Export (CTRL+E)>FILLED OUTLINE>Export>Verify EPS Dialog box>OK.
[0104] (6) Export two+PLT (HPGL) files for the FIBER Laser to be used in PHASE 4. Choose a location that can be easily retrieved for PHASE 4:
(a) Select the MASTER file using the Pick Tool and Export>LASER MASTER.plt. (This file has everything: Both Outlines, Rivet Holes & Crosshairs.) Go to File>Export (CTRL+E)>Make sure Selected Only is Checked>File Type is PLT (HPGL)>LASER MASTER>Export>HPGL Dialog Box>OK. (b) Select the OUTLINE file using the Pick Tool and Export>OUTLINE.plt. (This file is internal Outline only.) Go to File>Export (CTRL+E)>OUTLINE>Export>HPGL Dialog Box>OK. (c) Select the RIVET HOLE file(s) using the Pick Tool and Export>LG HOLE.plt. Go to File>Export (CTRL+E)>LG HOLE, MD HOLE or SM HOLE>Export>HPGL Dialog Box>OK.
[0108] (7) PHASE 2 is now complete.
[0109] PHASE 3: Preparing the Final Art to Laser Ablate in PHASE 4 and then Color Print the Firearm Part as the Finish Step in PHASE 5.
[0110] (1) In Adobe Photoshop start a new file—Go to File>New, this brings up the New Dialog Box:
(a) Name the file TEMPLATE. (b) Create a box larger than firearm part—insert dimensions in width and height. (Example: 8×8 inches.) (c) Set Resolution to 600 dpi. (d) Set Color Mode to CMYK and 8 bit. (e) In Background Content>White. (f) Click OK—this brings up the newly created Page.
[0117] (2) Import both EPS Files saved in PHASE 2:
(a) Go to File>Place Embedded>Choose the FILLED OUTLINE.eps file and Double-Click or click Place. Click the Move Tool>Place the File? (This brings up the Place the File? dialog box) and click Place (shortcut—Click Enter); and (b) Go to File>Place Embedded>Choose the RIVETS & OUTLINE.eps file and Double-Click or click Place. Click the Move Tool>Place the File? This brings up the Place the File? dialog box and click Place (shortcut—Click Enter).
[0120] (3) Open picture(s) and place artwork and edit/collage pictures in area of Shape. This step is where the artist takes all the photos and backgrounds and blends them together to create the final Art Image(s) PDF files.
[0121] (4) Save before merging artwork together.
[0122] (5) Now merge all photo layers together:
(a) To merge the Art Layers together: CTRL+Click on each Art Layer to select>Merge Layers (CTRL+E). (b) Rename Layer to ART LAYER (Double Click on name to change it).
[0125] (6) Save as Merged Art as a Photoshop.PSD File.
[0126] (7) CTRL+Left Click on Smart Object Thumbnail of the Filled Outline Layer—This makes a dotted outline appear.
[0127] (8) Go to Select>Modify>Contract and set at 30. Click OK.
[0128] (9) Select the Smart Object of the Filled Outline Layer and go to Select>Refine Edge>Adjust Edge>Feather set to 20, Click OK.
[0129] (10) Go to Select>Inverse and highlight Art Layer and Delete (on keypad)—The background is now deleted.
[0130] (11) Turn Filled Outline Off by clicking the Eye Ball.
[0131] (12) (CTRL+D)—Gets rid of dotted line.
[0132] (13) Right click on the Art Layer, select Blending Options in drop down menu. Click Stroke then click right button on mouse—make sure position is outside and set size to 40. Click Color and choose whatever color the background is desired to be. Hit OK.
(a) Use the eye dropper to choose a color from the Art. (b) The eye dropper appears when the cursor hovers over Art.
[0135] (14) CTRL+Left Click on the Smart Object Filled Outline Thumbnail.
[0136] (15) Go to Select>Inverse and highlight Art Layer and Delete (on keypad).
[0137] (16) (CTRL+D) to deselect.
[0138] (17) Using the Crop Tool (C) crop image around the shape—click Move Tool>Crop. This is where we crop the image smaller than the box size we made in 1b above.
[0139] (18) Center the Art Layer (vertically and horizontally) within the newly created Crop Box—Select Art Layer and Background by using CTRL+Click on both layers then up in the toolbar (make sure to use Pointer Tool and not Crop Tool):
(a) Select the Line Horizontal Centers Tool. (b) Select the Line Vertical Centers Tool.
[0142] (19) Left Click>Right Click on Art Layer and in menu select Rasterize Layer Style.
[0143] (20) CTRL+Left Click on the Art Layer Thumbnail.
[0144] (21) On bottom right corner click Create a New Layer and rename layer to CYAN.
[0145] (22) In left hand menu click Set Foreground Color and set C to 100% and M, Y and K to 0%. Click OK. Grab Paint Bucket Tool in same menu.
[0146] (23) Hover over Art and Left Click to fill with color.
[0147] (24) On bottom right corner click Create a New Layer and Rename Layer to MAGENTA.
[0148] (25) In left hand menu click Set Foreground Color and set M to 100% and C, Y, and K to 0%. Click OK. Grab Paint Bucket Tool in same menu.
[0149] (26) Hover over Art and Left Click to fill with color.
[0150] (27) In top menu select Image and scroll down to Image Size. Jot down Length and Width and hit OK.
[0151] (28) Click (CTRL+D) to deselect. Click on Move Tool.
[0152] (29) Turn Eye Off on every Layer except CYAN and Background. Save As WHITE.pdf. Go to File>Save As >WHITE.pdf and choose Photoshop PDF under File Type. When dialog box appears click OK. Another dialog box will appear this time Check Preserve Photoshop Editing Capabilities, Check Embed Page Thumbnails, Check Optimize for Fast Web Preview, and Uncheck View PDF after saving. Click Save PDF.
[0153] (30) Turn Eye Off on every layer except MAGENTA and Background. Save As PRIMER.pdf. Go to File>Save As >PRIMER.pdf and choose Photoshop PDF under File Type. When dialog box appears click OK. Another dialog box will appear this time Check Preserve Photoshop Editing Capabilities, Check Embed Page Thumbnails, Check Optimize for Fast Web Preview, and Uncheck View PDF after saving. Click Save PDF.
[0154] (31) Turn Eye Off on every layer except ART LAYER and Background. Save As ART LAYER.pdf. Go to File>Save As >ART LAYER.pdf and choose Photoshop PDF under File Type. When dialog box appears click OK. Another dialog box will appear this time Check Preserve Photoshop Editing Capabilities, Check Embed Page Thumbnails, Check Optimize for Fast Web Preview, and Uncheck View PDF after saving. Click Save PDF.
[0155] (32) Make sure all the Eyeballs are turned on before final Save. Save as FINAL.psd.
[0156] (33) PHASE 3 is now complete.
[0157] PHASE 4: Using the FIBER Laser, Laser Ablate the Firearm Part in Preparation to be Color Printed in PHASE 5.
[0158] PHASE 4—Step 1—Now that the Final Art has been Created Successfully, Manipulate the Final Art Image Until it Lines Up Exactly with the Actual Firearm Part. The End Goal is to have the Final Art Image and the Firearm Part Superimposed with an Identical Aspect Ratio.
[0159] (1) Import the file LASER MASTER.plt. Go to File>Import (CTRL+I) and navigate to the file. Make sure File of Type is HPGL File.*plt (a user will now be able to see all the Vector files created for the firearm part including the Laser Master). Highlight the LASER MASTER File and click Open.
[0160] (2) Turn Outline OFF—Under the OBJECT INFO TAB (upper right)—Uncheck Mark Outline>Apply.
[0161] (3) Check sizing under the MOVE/SIZE TAB under the Outline Section (verify the Dimensions Sheet aspect ratio—X and Y dimensions—are the same as in CoreIDRAW).
[0162] (4) Import all rivet holes. LG HOLE.plt; MD HOLE.plt; SM HOLE.plt. Go to File>Import (CTRL+I) and navigate to the first rivet hole PLT (Vector Line File) then click Open. Then under the OBJECT INFO TAB—Uncheck Mark Outline>Apply. Repeat until all rivet holes have been imported.
[0163] (5) Using the Mouse, click the corner of the newly imported rivet holes and move each one close to desired location. Once they are all close, they will be moved to the exact location:
(a) Before making any moves, change the Nudge Step—With the first rivet hole selected, on the toolbar select SETTINGS>SYSTEM>VIEW TAB (Default) and change the NUDGE STEP to 0.001 for both X and Y and click Apply then OK. (b) Use the Zoom Tool to get a better view of the rivet holes. Simply click the Zoom Tool and create a box around the area to magnify. (c) Now select the first rivet hole circle and move it to the exact location by using the appropriate CTRL_ARROW (up, down, left, right).
[0167] (6) Import the file OUTLINE.plt.
(a) Go to File>Import>OUTLINE.plt>Open. (b) Make sure power setting is set to Deep under the Laser TAB (Deep is always default). (c) Change number of passes to five under the OBJECT INFO TAB>Apply. (d) Make sure the Outline File lines up with the Master—Using the Zoom Option and Nudge Option from (5) above. (e) Verify size to CoreIDRAW Dimensions under the MOVE/SIZE TAB. (f) Save the file as LASER.sjf. File>Save As >Name the File>Save.
[0174] (7) Mount fixture and firearm part on the laser bed and turn vacuum on.
[0175] (8) Move the XYZ Coordinates until close to the crosshair on the vellum which has been trimmed down and aligned on the firearm part surface:
(a) Put firearm part on laser table with vellum superimposed clearly showing the crosshair. Level firearm part using fixture, screw jacks, and bullseye. (b) In order to move the laser table so the pendulum is aligned with the crosshair, with nothing selected click on the CONTROL TAB (upper right). (c) In the CONTROL TAB move X, Y & Z coordinates until the pendulum is aligned with the crosshair>Go. (d) Remove Foc-Align Cap and vellum. (e) Using the fiber focal stick, adjust to exact focal length. (f) Adjust Z dimension −0.06″ after exact focal length is determined.
[0182] (9) Now it is time to double check the rivet holes on the vellum/firearm part by using the Red Box laser feature:
(a) Select all rivet hole(s) and Click (F1) (this brings up the MARK Dialog Box), Check Individual Border in Mark Dialog Box. Click (F1) (turns on Red Box Feature and starts laser pointer). (b) Adjust X and Y dimensions until aligned. (c) Apply Yellow Vinyl Paint Mask:
(i) Clean the surface of the firearm with Wurth Clean-Prep and a Microfiber Cloth. (ii) Apply Yellow Vinyl Paint Mask to the surface of the Firearm Part.
(d) The Red Box laser pointer will actually outline the rivet hole to verify the firearm part is in the correct location. (e) Repeat Red Box verification until all check points are confirmed. (Rivet hole(s), both outer and inside outline, ejection port, straight edges, four corners etc.) (f) If adjustments are necessary, move the laser following the XYZ coordinates instructions in (8) above.
[0191] (10) Verification of all measurements is now complete. The paint mask is ready to be laser cut.
[0192] PHASE 4—Step 2—Now that the Firearm Part is Perfectly Aligned; it is Ready to Laser Cut the Paint Mask.
[0193] (1) Make sure the firearm part is in the exact location. Double verify firearm part has NOT MOVED and is still LEVEL.
[0194] (2) If firearm part is lined up select the OUTLINE.plt only and laser outline:
(a) Remove FOC-Align Cover from the laser. Put glasses on. Make sure exhaust blower is on. (b) Click (F1) three times to run the laser. (First click brings up MARK Dialog Box, second click turns on the RED BOX and the third click RUNS the laser.)
[0197] (3) Peel mask away.
[0198] (4) Close the MARK Dialog Box—Stop>close Red Box.
[0199] PHASE 4—Step 3—Laser Ablate the Firearm Part.
[0200] (1) Make a COPY of the OUTLINE.plt by clicking (F5):
(a) Change number of passes from five to one under the OBJECT INFO TAB>Apply. (b) Fill the OUTLINE PLT under the FILL TAB select Enable (change to 90 degree fill with a spacing of 0.0012″ distance)>Apply. (c) Change Power setting under the LASER TAB to Gun Fill>Apply. (Power 30/Speed 10/Q 20/Spot Size 2—Gun Fill Pen #21.) (d) Make a copy by clicking (F5) of the above created OUTLINE PLT and change the FILL ANGLE under the FILL TAB to (−45 degree fill)>Apply. (e) Make a copy by clicking (F5) of the above created OUTLINE PLT and change the FILL ANGLE under the FILL TAB to (0 degree fill)>Apply. (f) Make a copy by clicking (F5) of the above created OUTLINE PLT and change the FILL ANGLE under the FILL TAB to (45 degree fill)>Apply.
[0207] (2) Select all four passes created above and copy them by clicking (F5). A total of eight passes has been created.
[0208] (3) Create the final pass (an Outline Pass only with three passes)>Copy the first OUTLINE.PLT by clicking (F5)>Change Passes from five to three under the Object Info Tab>Change the Power Setting to Gun Fill under the Laser Tab.
[0209] (4) LASER ENGRAVE—Select all the above created layers>Click the second OUTLINE.PLT file in the left joblist>click Shift then select the last OUTLINE.PLT Layer. Safety glasses on. Click (F1) three times to run the laser: First click brings up MARK dialog box, Second click turns on the RED BOX, and the Third click RUNS the laser.
[0210] (5) Clean the surface of the firearm part again with Wurth Clean-Prep and a Microfiber Cloth.
[0211] (6) Click STOP>Close (Red X Box).
[0212] (7) Save.
[0213] (8) PHASE 4 is now complete.
[0214] PHASE 5: Using the MIMAKI UV Printer, Color Print the Firearm Part as the FINISH Step.
[0215] (1) Install firearm fixture on bed of printer.
[0216] (2) Wipe surface of firearm part with Wurth Clean-Prep and put it in the fixture.
[0217] (3) Open Mimaki Rasterlink6 on desktop and say YES to pop-up.
[0218] (4) Lower table so printer head clears the fixture:
(a) This is done on actual machine. (b) Function>Down Arrow to Head Height>Enter>Down Arrow to Table Spacer>Enter>(change to 0>Enter>Down Arrow to Media Thickness>Enter>146.3 mm>Enter>END twice to get back to main screen).
[0221] (5) Open the ART LAYER.pdf. Click File>Open>ART LAYER.pdf>Open.
[0222] (6) Under Joblist scroll down to find the file and click once on it.
[0223] (7) In Menu on right hand side go to General Print (ALT+G) (verify Art size matches PhotoShop size on Dimensions Sheet).
(a) Under Scale check Valid Pixel and change size if need be. (b) Move where the image prints under Position. Position>Change Scan & Feed to correct Dimensions (based on a Scan which is horizontal of 12″ and Feed which is vertical of 9.25″) (Formula: Dimensions of Artwork divided by 2, subtract this from the above-mentioned Scan and Feed and plug that in as the Dimensions for Position) (write down Dimensions to be used in the future). To preview go to the Jig Print (ALT+J). (This gives a visual, if it is necessary to move, repeat above.)
[0226] (8) In same menu on right hand side click Quality (ALT+Q) and under Print Quality go to resolution and select 720×1200 VD.
[0227] (9) Put clear acrylic cover over firearm part and tape down a piece of inkjet paper on area it is going to print.
[0228] (10) In Menu on right hand side click Execution (ALT+X)>Make sure Rip & Print is Selected>click Start.
[0229] (11) Put in Remote Mode done on actual machine.
[0230] (12) Peel paper after printing.
[0231] (13) Create white Layer by importing the WHITE.pdf file:
(a) File>Open>Choose WHITE.pdf>Click Open. (b) Click on White Color Layer in Joblist. (c) General Print Tab (ALT+G)>Click Valid. (d) Change location of art to exact same as Color Layer. (e) Click Quality (ALT+Q) and change to 720×1200 VD. (f) Click Properties (ALT+I)>Under Job Attributes change to Mono Color (g) In Job Attributes dialogue box under Source Color check Cyan>Check White & White>OK.
[0239] (14) Create primer Layer by importing the PRIMER.pdf file.
(a) File>Open>Choose PRIMER.pdf>Click Open. (b) Click on Primer Color Layer in Joblist. (c) General Print Tab (ALT+G)>Click Valid. (d) Change location of art to exact same as Color Layer. (e) Click Quality (ALT+Q) and Change to 720×1200 VD. (f) Click Properties (ALT+I)>Under Job Attributes change to Mono Color. (g) In Job Attributes dialogue box under Source color check Magenta>Check Primer>OK.
[0247] (15) Double check that all layers match size, resolution and position under General Print (ALT+G) and Quality (ALT+Q).
[0248] (16) Tape the Clear Transparency on the fixture over the print area.
[0249] (17) Highlight the Primer Layer in Joblist and run the Primer Layer to make sure firearm is straight.
[0250] (18) In menu on right hand side click Execution (ALT+X) and click Rip and Print for Primer Layer ONLY>Start.
[0251] (19) Use fixture to align firearm part to primer print.
[0252] (20) Remove acrylic printing surface and all spacers. (Make sure Firearm Part is still level.)
[0253] (21) Lower table so printer head clears the firearm part:
(a) Done on actual machine. (b) Put machine in Local Mode by hitting Remote Button. (c) Function>Down Arrow to Head Height>Enter>Down Arrow to Media Thickness>Enter>TBD MM. (d) Put MM Dimension on Dimensions Sheet. (e) Verify nothing is sticking up (including yellow mask). (f) Put black plastic piece in front of firearm so printer has something to see. (g) Put in Remote Mode (done on actual machine). Make sure laser does a Micro Adjustment to verify focal length is accurate, otherwise it will need to be adjusted.
[0261] (22) Choose Print Only and click Start. After primer has printed, make sure it is printed centered on ablated surface. (If not make adjustments.)
[0262] (23) Select White Layer Only and click (ALT+X), Rip & Print, Start.
(a) Verify white is solid/bright enough, will probably have to run multiple times. (b) To repeat click print only then start (or the black button). (c) On dimensions sheet write down how many passes were run.
[0266] (24) Select Art Layer Only and the click (ALT+X), Rip & Print, and then click Start.
[0267] (25) Release vacuum and remove firearm part.
[0268] (26) Peel mask.
[0269] (27) PHASE 5 is now complete.
[0270] It is also important to note that the construction and arrangement of the elements of the invention as shown in the exemplary embodiments is illustrative only. Although only a few embodiments of the present innovations have been described in detail in this disclosure, those skilled in the art who review this disclosure will readily appreciate that many modifications are possible (e.g., variations in sizes, dimensions, structures, shapes and proportions of the various elements, values of parameters, mounting arrangements, use of materials, colors, orientations, etc.) without materially departing from the novel teachings and advantages of the subject matter recited. For example, elements shown as integrally formed may be constructed of multiple parts or elements shown as multiple parts may be integrally formed, the operation of the interfaces may be reversed or otherwise varied, the length or width of the structures and/or members or connector or other elements of the system may be varied, the nature or number of adjustment positions provided between the elements may be varied. It should be noted that the elements and/or assemblies of the system may be constructed from any of a wide variety of materials that provide sufficient strength or durability, in any of a wide variety of colors, textures, and combinations. Accordingly, all such modifications are intended to be included within the scope of the present innovations. Other substitutions, modifications, changes, and omissions may be made in the design, operating conditions, and arrangement of the desired and other exemplary embodiments without departing from the spirit of the present innovations.
[0271] It will be understood that any described processes or steps within described processes may be combined with other disclosed processes or steps to form structures within the scope of the present disclosure. The exemplary structures and processes disclosed herein are for illustrative purposes and are not to be construed as limiting.
[0272] It is also to be understood that variations and modifications can be made on the aforementioned structures and methods without departing from the concepts of the present invention, and further it is to be understood that such concepts are intended to be covered by the following claims unless these claims by their language expressly state otherwise. | A method of customizing the surface of a firearm and a resulting customized firearm includes laser ablating a predetermined metallic surface area of the firearm. An image that fits within the borders of the laser ablated surface is then ink-printed onto the laser ablated surface of the firearm. | 1 |
FIELD OF THE INVENTION
The present invention relates generally to an apparatus and method for making decorative bows of various shapes, sizes, colors, and varieties which have a professionally-made appearance, and specifically to an apparatus and method for making decorative bows wherein the apparatus forms a part of the completed bow.
BACKGROUND OF THE INVENTION
The prior art contains several examples of apparatuses and methods for producing decorative bows.
U.S. Pat. No. 3,021,038 to Dean (1962) uses a plastic form to produce bows. The only element of this prior art device common to the present invention is an opening in the center of the form. The form is shaped differently than that of the present invention and the finished bow of the prior art device does not look similar to that of the present invention. Also, the bow of the prior art device has a lump in the bottom caused by stapling, and as a result it will not lie flat.
U.S. Pat. No. 3,229,870 to Capstick (1966) uses a plastic bow-making form which also has a different shape and different method of bow formation than the present invention. This prior art device has long legs with bevels or sharp points on the end of each leg that requires that the ribbon be hung or hooked midway and balanced on the end of a leg. The prior art device is difficult to use with plastic ribbon, which can only be hung around the end of each leg once, and even then with difficulty.
U.S. Pat. No. 4,651,908 to Ford (1987) discloses a form with a circular opening in its middle which facilitates the formation of the bow by allowing stapling through the bow ribbon before removing the ribbon from the form. The legs of the form are sufficiently flexible that when the bow is made, the points may be flexed inward to release the loops of the bow.
The prior art concerning apparatuses and methods for producing decorative bows of professional quality has generally been disappointing to consumers of such decorative bows.
First, the directions for the prior art devices tend to be complex and difficult to understand, resulting in mismade and inferior-looking bows.
Second, some prior art devices are prohibitively expensive for the average consumer of decorative bows. For the average consumer who only needs decorative bows once or twice a year on special occasions, the purchase of an expensive bow-making device is economically unjustifiable.
Third, the prior art apparatuses and methods can only produce a limited number of styles of decorative bows. Each apparatus or method can only use a limited number of materials to produce a limited range of sizes of bows. Some prior art is even limited to making only certain colors of bows.
Fourth, none of the prior art noted above utilize a bow-making form which becomes a permanent part of the completed bow, wherein the completed bow may be left intact for permanent use or disassembled so that the form may be reused to make another bow.
Finally, none of the prior art is directed towards apparatuses or methods for making what are commonly termed "pew bows", i.e. large bows appropriate for use as pew decorations.
In view of the difficulties in making inexpensive decorative bows with aesthetically pleasant appearances, :most consumers simply opt to buy their bows from professional florists or the like, regardless of the higher expense.
SUMMARY OF THE INVENTION
The bow making form of the present invention is directed to a form for making decorative bows from flexible bow material. Such bow material has a width and a length substantially greater than the width. The length of the bow material includes several length portions, each of which is used to form a loop within the completed bow. The form comprises a top face, a bottom face, a generally circular perimeter bounding the top face and the bottom face, and a central core with a central aperture extending from the top face to the bottom face. The form includes a plurality of spaced peripheral openings extending from the top face to the bottom face at positions between the central aperture and the perimeter to define struts between the peripheral openings which extend radially from the central core to the perimeter. Each of the peripheral openings has at least the same size as the central aperture.
The present invention is additionally directed to a method for making decorative bows from flexible bow material and a bow making form. The bow material includes a width and a length, which is substantially larger than the width. The length includes two ends and a plurality of length portions therebetween. The form includes a top face, a bottom face, a generally circular perimeter bounding the top face and the bottom face, a central core, and a plurality of spaced peripheral openings located between the central core and the perimeter and extending from the top face to the bottom face. The method of making decorative bows comprises: doubling a length portion onto itself so as to form the length portion into a loop; inserting the loop into a peripheral opening from the bottom face so that the loop is contained within the peripheral opening and extended from the top face; and forming another length portion into an additional loop and repeating the preceding steps (a) and (b) for an additional peripheral opening within the form.
Besides having the object of overcoming the disadvantages of the prior art noted above, the bow making form of the present invention has several additional objects:
to provide a bow making form that produces bows of professional quality and appearance;
to provide a bow making form that is simple to use by those who are not skilled in the art of bow making, thus eliminating the need for professional bow-making services;
to provide a bow making form that is relatively inexpensive;
to provide a bow making form that eliminates the need for tying or the use of fasteners (e.g. staples, thumbtacks, pegs, or pins) to complete the bow;
to provide a bow making form wherein the completed bow has a flat bottom, allowing its easy affixment to surfaces;
to provide a bow making form that allows flexibility in the size, color, and selection of bow materials;
to provide a bow making form which allows the user to make a single bow which contains a variety of different bow materials of different sizes and colors;
to provide a bow making form wherein the form constitutes an integral part of the completed bow;
to provide a bow making form wherein the bow may be disassembled to remove the form for reuse within a different bow, allowing the form to be recycled rather than discarded;
to provide a bow making form wherein the same form may be used to make differently sized bows;
to provide a bow making form wherein the completed bow has as many layers of loops of bow material as the user desires;
to provide bow making forms of different sizes so that a wide range of differently sized bows may be made; and
to provide a bow making form which allows the manufacture of decorative bows for uses such as (but not limited to) pew bows, floral arrangements, holiday wreaths and baskets, candle rings, or decorations for gifts, doors, walls, tables, and the like.
The bow making form of the present invention provides a simple, inexpensive, reusable bow making form that can be used by practically anyone. The bow making form allows greater creativity in bow making because it may use various bow materials (e.g. ribbons) of various colors and sizes to make the bow without the need for fasteners or tying to complete the bow and hold it intact.
Further objects, features and advantages of the invention will be apparent from the following detailed description when taken in conjunction with the drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of the bow making form as seen from the top.
FIG. 2 is a perspective view of the bow making form of FIG. 1 including a bow ribbon inserted in the first peripheral opening of the bow making form.
FIG. 3 is a perspective view of the bow making form of FIG. 1 including a bow ribbon inserted in the first and second peripheral openings of the bow making form.
FIG. 4 is a perspective view of the bow making form of FIG. 1 including a bow ribbon inserted in all of the peripheral openings of the bow making form.
FIG. 5 is a another perspective view of the bow making form of FIG. 4.
FIG. 6 is a perspective view of the bow making form of FIG. 1 wherein a bow ribbon has been inserted in all of the peripheral openings of the bow making form and also within the central aperture of the bow making form.
DETAILED DESCRIPTION OF THE INVENTION
In the drawings, wherein the same or similar features are designated by like reference numerals, the bow making form of the present invention is shown generally at 10.
The form 10 has a generally circular perimeter 38 bounding a top face 32 and a bottom face 34. The form 10 includes a central core 36 wherein a central aperture 28 extends from the top face 32 to the bottom face 34. A plurality of peripheral openings 12, 14, 16, 18, 20, 22, 24 and 26 are located between the central core 36 and the perimeter 38. These peripheral openings 12-26 extend from the top face 32 to the bottom face 34, and are preferably arranged symmetrically about the central aperture 28 between the central core 36 and the perimeter 38. The peripheral openings 12-26 are also preferably spaced at equal distances from the central aperture 28, and evenly about the form 10 so that each is the same distance from its adjacent peripheral openings. The peripheral openings 12-26 within the form 10 define the struts 61, 63, 65, 67, 69, 71, 73, and 75, which extend from the central core 36 toward the perimeter 38.
As will be described below, the peripheral openings 12-26 will hold the peripheral loops of the completed bow, and the central aperture 28 will hold one or more central loops. Certain configurations of peripheral openings 12-26 have been found to hold bow material better than others. The peripheral openings 12-26 are ideally shaped trapezoidally, with a larger width A located near the outer edge of the form 10 which gradually narrows in size toward a smaller width B located near the central aperture 28. Since the peripheral openings 12-26 will generally hold more loops than the central aperture 28, the peripheral openings 12-26 are preferably the same size as, or slightly larger than, the central aperture 28.
The preferred embodiment of the bow making form 10 is a piece of plastic approximately 2 mm thick, with a generally circular perimeter and a radius of about 7 cm. The peripheral openings 12-26 have an area of approximately 4.5 cm 2 , and the central aperture 28 has an area of approximately 4 cm 2 . This sizing has been found to produce a well-proportioned bow having a professionally-made appearance when bow materials with widths of 8-15 cm are used within the form 10. If narrower or wider bow materials 30 are to be used within the form 10, good results are obtained with forms 10 sized proportionately to the preferred embodiment.
The description of the preferred embodiment of the form 10 should not be construed as limiting the scope of the invention as to its size, shape, or material of the form 10, but as merely providing an illustration of the presently preferred embodiment of the invention. Alternate embodiments of the form 10 are contemplated and function equally well as the preferred embodiment. For example, the form 10 may have a different size, as may the central aperture 28 and the peripheral openings 12-26. Similarly, the form 10, central aperture 28, and the peripheral openings 12-26 may be differently shaped (e.g. circles, pear-shapes, teardrops, ovals, etc.). The number of peripheral openings 12-26 and struts 61-75 may vary.
The operation of the bow making form 10 is outlined as follows. First, the user must obtain a piece of flexible bow material 30 having a ribbon-like shape, with a length generally much greater than its width. The bow material 30 illustrated in FIGS. 2-6 is, for example, a piece of fabric approximately 11 cm wide and about 5 m long. This material 30 and its associated dimensions are chosen for the example because the material 30, when used with the preferred embodiment of the bow making form 10 as shown in FIG. 1, forms a well-bodied bow measuring approximately 27 cm in diameter with two layers of fabric loops. However, the user can use any length or type of bow material 30 depending upon the size of bow desired.
FIG. 2 illustrates the creation of the first of several bow loops within a bow. The user simply inserts the material 30 within a peripheral opening 12 of the form 10 from the bottom face 34 of the form 10 to form a loop 40 which protrudes from the top face 32. The material 30 is inserted through the bottom face 34 of the form 10 and pulled through the top face 32 of the form 10 until the loop 40 reaches the desired size. The user then measures another length from the material 30 for the next loop 42 of the bow and inserts this length in an adjacent peripheral opening 14 from the bottom face 34 to form the next loop 42, as shown in FIG. 3. Slack in the material 30 at the bottom face 34 of the form 10 may be taken up by holding the first loop 40 and pulling the adjacent loop 42. This removal of slack at the bottom face 34 allows the completed bow to lie on a flat surface with no lumps underneath. The procedure is then repeated for the remaining six peripheral openings 16-26, as shown in FIGS. 4 and 5. Loops 44, 46, 48, 50, 52, and 54 are sequentially formed and inserted within peripheral openings 16, 18, 20, 22, 24, and 26, thereby completing a bow 58 with a single layer of material 30 loops.
Any material 30 not used for loops within the bow 58 may be cut off or used as a streamer. However, if bows with multiple layers of loops are desired, the user can then go around the form 10 again, inserting additional material 30 within the peripheral openings 12-26 as many times as the size of the peripheral openings 12-26 will accommodate. The second layer of loops may be sized differently from the first layer of loops. Tapered peripheral openings 12-26, having a trapezoidal or similar shape wherein the peripheral openings are narrower adjacent the central aperture 28, are helpful because they hold the material as the peripheral openings 12-26 are filled with material from their inner sides B near the central aperture 28 to their outer sides A adjacent the perimeter of the form 10.
At some point, if the user so desires, the user can insert a loop 56 of the material 30 through the central aperture 28 using the same procedure as with the peripheral openings 12-26. As shown in FIG. 6, this creates body in the center of the bow 58. This step is preferably done when almost all of the length of the bow material 30 has been inserted within some or all of the peripheral openings 12-26, and only a small length of excess material remains, enough to insert within the central aperture 28 plus a little extra length. The extra length can then function as a streamer. Alternatively, it may simply be cut off.
In addition, when the basic bow 58 has been completed as detailed above, the entire procedure can be repeated with another length of different material 30. The loops of the different material 30 may be larger or smaller than the previous loops to suit the user's preference. As discussed above, the material 30 is inserted through the peripheral openings 12-26 from the larger portion A of the peripheral openings and tucked down to the smaller portion B of the peripheral openings, thus causing the smaller portion B to hold the material 30 in place.
Once the above steps are completed, the user can then straighten or fluff the loops of material to create the desired appearance in the bow 58. Any remaining length of material can be used as a streamer or cut off. An exemplary completed bow 60 with a single layer of loops is shown in FIG. 6.
If the user wishes, the bow 60 may later be taken apart by pulling the material 30 loops from the peripheral openings 12-26 and/or the central aperture 28. Both the form 10 and the material 30 may then be retained for reuse. The form 10 can be used to make another bow 60 with either the same or different material 30.
It is understood that the invention is not confined to the particular construction and arrangement of parts herein illustrated and described, but embraces such modified forms thereof as come within the scope of the following claims. | A form for making decorative ribbon bows. The form includes a circular body having a central aperture surrounded by a series of peripheral openings. The peripheral openings are preferably tapered so that they are narrower adjacent the central aperture and wider adjacent the perimeter of the body. A loop of bow material is inserted into each peripheral opening to form the bow. Each peripheral opening may accommodate one or more loops of bow material. The form may separately or simultaneously accommodate different bow materials having different sizes and colors. When the bow is completed, the form remains a permanent part of the bow. The bow may be disassembled so that the form and bow material may be reused. | 3 |
FIELD OF THE INVENTION
[0001] The present invention relates generally to a food waste disposer, and more particularly to an over-molded vibration isolation gasket for mounting a food waste disposer to a sink.
BACKGROUND OF THE INVENTION
[0002] Conventional food waste disposers are typically coupled to a sink by a mounting gasket, which is typically composed of rubber. The mounting gasket serves as the primary seal between the sink and the disposer and preferably also prevents the transmission of vibration from the disposer to the sink.
[0003] In a prior art approach, and referring to FIG. 1, a conventional connecting assembly 40 and rubber mounting gasket 80 are used to attach the disposer to the sink 30 . The conventional connecting assembly 40 of FIG. 1 is substantially similar to that described in U.S. Pat. No. 3,025,007, which is incorporated herein by reference. The connecting assembly 40 includes a sink collar 34 , a seal plate 50 , a mounting flange 60 , and a support flange 70 .
[0004] During assembly, the sink collar 34 , seal plate 50 , and mounting flange 60 are first secured in place around and underneath the sink 30 . More specifically, the sink collar 34 is positioned within the drain opening 32 of the sink 30 , leaving drain flange 36 to rest around the drain opening 32 as shown. During assembly, a gasket 54 and the seal plate 50 are slipped onto the sink collar 34 now appearing on the underside of the sink 30 . The mounting flange 60 is then slipped onto the collar 34 , and a snap ring 62 is seated within an annular recess on the collar 34 . Studs 66 are then screwed through threaded holes 64 in the mounting flange 60 until they contact the underside of a projecting surface of the seal plate 50 , thus pressing the gasket 54 between the seal plate 50 and the sink 30 . (Three studs 66 are normally used, but only one is shown in the cross section of FIG. 1). The mounting flange 60 has inclining flanges 68 onto which the remainder of the disposer (and associated hardware) can be screwed to fix the disposer into position underneath the sink, as will be explained in further detail later.
[0005] The food waste disposer includes a container body 10 and a top container cover 20 , both preferably formed of metal. The container body 10 has an outwardly extending lip 12 to which edge 22 of the container cover 20 is crimped to seal the top of the disposer. The container cover 20 includes a housing collar 24 that forms the inlet of the disposer. During assembly, the support flange 70 is positioned on the housing collar 24 of the housing, and the mounting gasket 80 is press fit onto an outwardly extending lip 26 of the extruded collar 24 to hold the support flange 70 in place. As shown, the support flange 70 contains inwardly bent tabs 78 .
[0006] When the disposer (with the support flange 70 in place) is to be affixed to the mounting flange 60 (already supported under the sink), the tabs 78 are positioned to meet with the inclining flanges 68 on the mounting flange 60 . Because the inclining flanges 68 are inclined, the tabs 78 (i.e., support flange 70 ) can be twisted with respect thereto, in effect, screw the disposer onto the mounting flange 60 to position the disposer in place underneath the sink 30 . To facilitate turning the support flange 70 , the support flange 70 is preferably formed with finger pads 76 . (Again, the support flange 70 normally contains three sets of tabs 78 and finger pads 76 , but only one such set is shown in the cross-section of FIG. 1). As the support flange 70 is twisted into place, it is brought closer to the mounting flange 60 due to the incline of inclined flanges 68 , thereby compressing the mounting gasket 80 therebetween, and further compressing the mounting gasket 80 against an inwardly projecting flange 38 of the collar 34 . In short, the flanges 60 and 70 compress the mounting gasket 80 to create a seal between the sink collar 34 and the housing collar 24 on the disposer. The mounting gasket 80 includes a plurality of pleats 87 formed across the drain opening to keep food waste from being ejected through the drain when the disposer is operating.
[0007] Food waste disposers produce noise during operation that is caused by the operation of the motor and by the impacting of food waste against the housing of the disposer. These sources produce vibrations having a broad frequency spectrum. The vibration of the disposer can be transmitted into the sink through the connection of the disposer with the sink, which produces objectionable noise in and around the sink. Such noise is particularly evident, for example, in installations with relatively thin stainless steel sinks that act as excellent resonators.
[0008] Unfortunately, the conventional connecting assembly 40 and mounting gasket 80 of FIG. 1 create a substantially rigid connection between the food waste disposer and the sink. In particular, vibration is hypothesized to travel through the solid metallic housing collar 24 , the compressed mounting gasket 80 , and the connecting assembly 40 to the sink 30 . Although vibration through the collar 24 is somewhat attenuated by the rubber material of the mounting gasket 80 that surrounds it, further dampening measures would be desirable, particularly if such measures did not significantly impact the structural integrity of the disposer or the manner in which it is affixed under the sink.
[0009] The reader is referred to the following U.S. patents for further background concerning ways of minimizing operation noise of food waste disposers, all of which are incorporated herein by reference in their entireties: U.S. Pat. Nos. 2,743,875; 2,894,698; 2,945,635; 2,951,650; 2,965,317; 2,975,986; 3,801,998; 3,862,720; and 5,924,635.
SUMMARY OF THE INVENTION
[0010] A vibration isolation gasket for mounting a food waste disposer to a sink is at least partially molded onto a portion of the housing of the disposer, and preferably to the disposer's container cover. The vibration isolation gasket preferably includes a rubberized and integrally-formed gasket portion, sleeve portion, and over-molded portion. The gasket portion couples to the drain opening and may contain pleats to prevent food ejection from the disposer. The sleeve portion connects the gasket and over-molded portions, bears the weight of the disposer as it hangs from the sink, and acts as the primary structure for reducing vibration-induced noise. The over-molded portion is preferably molded onto the top and bottom of the container cover, which is in turn crimped to the remainder of the disposer housing.
[0011] The foregoing summary is not intended to summarize each potential embodiment or every aspect of the present disclosure.
BRIEF DESCRIPTION OF THE DRAWINGS
[0012] The foregoing summary, a preferred embodiment, and other aspects of subject matter of the present disclosure will be best understood with reference to a detailed description of specific embodiments, which follows, when read in conjunction with the accompanying drawings, in which:
[0013] [0013]FIG. 1 illustrates a cross-sectional view of a conventional connecting assembly and mounting gasket according to the prior art;
[0014] [0014]FIG. 2 illustrates a cross-sectional view of an embodiment of a vibration isolation gasket for mounting a disposer to a sink;
[0015] [0015]FIGS. 3A-3D respectively illustrate side, perspective, top, and bottom views of the disclosed vibration isolation gasket of FIG. 2;
[0016] [0016]FIGS. 4A-4B illustrate bottom views of embodiments of top container covers for the disclosed vibration isolation gasket of FIG. 2;
[0017] [0017]FIG. 5 illustrates a cross-sectional view of a portion of the top container cover and over-molded portion for the disclosed vibration isolation gasket of FIG. 2;
[0018] [0018]FIGS. 6A-6B respectively illustrate graphs of sink vibration spectrums and acoustic spectrums comparing a disposer having a conventional mounting gasket with a disposer having the disclosed vibration isolation gasket; and
[0019] [0019]FIG. 7 illustrates a perspective view of another embodiment of a vibration isolation gasket.
[0020] While the disclosed vibration isolation gasket is susceptible to various modifications and alternative forms, specific embodiments thereof have been shown by way of example in the drawings and are herein described in detail. The figures and written description are not intended to limit the scope of the inventive concepts in any manner. Rather, the figures and written description are provided to illustrate the inventive concepts to a person of ordinary skill in the art by reference to particular embodiments, as required by 35 U.S.C. § 112.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
[0021] In the interest of clarity, it is understood that not all of the features for an actual implementation of a vibration isolation gasket for mounting a food waste disposer to a sink are described in the disclosure that follows. It will be appreciated, of course, that in the development of any such actual implementation, as in any such project, numerous engineering and design decisions must be made to achieve the developers' specific goals, e.g., compliance with mechanical and business related constraints, which will vary from one implementation to another. While attention must necessarily be paid to proper engineering and design practices for the environment in question, it should be appreciated that the development of a vibration isolation gasket for mounting a food waste disposer to a sink would nevertheless be a routine undertaking for those of skill in the art given the details provided by this disclosure.
[0022] Referring to FIG. 2, an embodiment of a vibration isolation gasket 100 for mounting a food waste disposer (not shown) to a sink 30 is illustrated in a cross-sectional view. In contradistinction to the prior art discussed earlier, the disclosed vibration isolation gasket 100 is molded onto a portion of the disposer's housing, and preferably is molded onto a top container cover 120 of the housing. More specifically, gasket 100 contains three main rubberized portions in addition to the metallic container cover 120 that constitute the bulk of the gasket, viz., gasket portion 130 , sleeve portion 150 , and over-molded-portion 170 . Over-molded portion 170 is so named because that portion is molded over the metallic container cover 120 . More specifically, over-molded portion 170 preferably constitutes an upper over-mold 172 and a lower over-mold 174 .
[0023] The rubberized portions 130 , 150 , and 170 are preferably integrally formed over the container cover 120 , which can be accomplished by placing the container cover 120 inside a mold into which molten rubber is poured (or injected) and cured. The rubber material used for these portions preferably constitutes a flexible material, such as Nitrile rubber or ethylene propylene diene terpolymer (EPDM) rubber. The cover 120 is preferably formed of stainless steel, which is approximately 0.02 to 0.04-inch thick.
[0024] As noted, it is preferable to form the molded portions 130 , 150 , and 170 onto the container cover 120 , and then to affix the container cover 120 to the remainder of the disposer body. In this regard, the container cover 120 has an edge 122 that is crimped onto a lip 12 of an upper container body 10 of the disposer's housing. The edge 122 is approximately {fraction (1/8)}-inch long prior to its crimping to the lip 12 . A seal (not shown) is used between the attachment of the container cover 120 and the lip 12 . In an alternative arrangement, the top container cover 120 and upper container body 10 can be integrally formed, but such an integral arrangement is not preferred due to potential problems associated with molding the disclosed vibration isolation gasket 100 to such a large housing component. In particular, the upper container body 10 can act as a significant heat sink, which substantially increases the processing time. Consequently, it is preferred that the vibration isolation gasket 100 be molded onto a separate housing component, such as the top container cover 120 in the present embodiment.
[0025] Once formed onto the container cover 120 , the support flange 70 is pressed over the deformable gasket portion 130 to facilitate connection of the disposer to the sink 30 as disclosed earlier in the Background section of this disclosure. As the details of the conventional connecting assembly 40 are substantially similar to those described in the Background section of the present disclosure, the structure and function of its components are not repeated here.
[0026] The disclosed vibration isolation gasket 100 and top container cover 120 are illustrated in respective side, perspective, top, and bottom isolated views in FIGS. 3 A-D. (For illustrative purposes, the edge 122 of the container cover 120 is shown not crimped in FIGS. 3A-4B, as it would be before attaching to the container body of the disposer.) The gasket portion 130 mounts to the sink 30 with the connecting assembly 40 as just discussed. The sleeve portion 150 supports the weight of the disposer once it is positioned under the sink. The over-molded portion 170 as noted connects to the housing of the disposer, e.g., container cover 120 . All of these portions 130 , 150 , and 170 work to reduce the transfer of vibration from the disposer to the sink. In addition, and as in the prior art, a plurality of pleats 137 are preferably formed within a central opening 136 of the gasket portion 130 to keep food waste from being ejected through the opening 136 when the disposer is operating. However, the use of pleats 137 in connection with the gasket portion 130 is not strictly necessary.
[0027] As best shown in FIG. 3A, the sleeve portion 150 preferably has a smaller radial dimension than that of the gasket portion 130 such that it forms a recess in the disclosed gasket 100 . In addition, the sleeve portion 150 preferably has a smaller axial dimension than that of the gasket portion 130 . In one example of the disclosed gasket 100 , the sleeve portion 150 preferably has an outside diameter d 1 of approximately 3¼-inches and a height h 1 of approximately {fraction (1/4)}-inch, while the gasket portion 130 preferably has an outside diameter d 2 of approximately 4-inches and a height h 2 of approximately {fraction (1/2)}-inch. Preferably, the sleeve portion 150 has a wall thickness of about ⅛ to ¼-inch and more preferably 0.180-inch, but in any event should be thick enough to support the weight of the disposer (as much as 20 pounds). The disclosed molded gasket 100 is estimated to withstand pullout forces of about 100-lbs. or more.
[0028] As noted, rubberized portions 130 , 150 , and 170 are preferably molded to the container cover 120 , and several methods can be used to facilitate a good mechanical connection between them and the (usually) metallic cover 120 . In this regard, FIGS. 4A-4B illustrate the underside of the container cover 120 before the formation of rubberized components. In FIG. 4A, holes 126 or like structures are formed through the cover 120 , which allows the upper and lower over-molds 172 and 174 (not shown in FIGS. 4A-4B) to touch therethrough, improving the connection between the molded components and the cover 120 . The size, number, and placement of the holes 126 can vary, so long as the structural integrity of the disposer is not compromised. Preferably, twelve holes 126 having a diameter of about ¼-inch are formed about the central opening 124 . The holes 126 are arranged so that the outer edges of the holes 126 lie within a diameter of about 5¼-inches of the cover 120 , which represents the preferred outer diameter d 3 of the upper over-mold 172 discussed above. Alternatively, as shown in FIG. 4B, the central opening 124 in the cover 120 (normally circular as in FIG. 4A) can have an irregular shape with a plurality of notches 125 formed therein, which can strengthen the attachment of the extruded material of the disclosed gasket 100 to the container cover 120 . Preferably, eight, radial notches 125 each having a radius of about 0.150-inch are formed about every 45-degrees around the central opening 124 . In addition to having notches or another irregular shape, the opening 124 can have curled edges or like structures (not shown) to remove potentially sharp edges that could cut into the molded material, or could be formed with irregularity on its surfaces (e.g., nooks or tabs) to improve adhesion. Moreover, the container cover 120 can have ribs formed thereon or can have an extruded edge around the opening 124 to improve adhesion. Additionally, the surface of the cover 120 can be roughened, for example, by acid etching, prior to the overmolding process. Other processes and structures well known in the art of overmolding can be used as well, as one skilled in the art will appreciate.
[0029] For the best adhesion, it is preferred that overmolded portion 170 has both an upper and lower over-mold 172 , 174 , but in a given design either of these over-molds could be deleted. Were only one over-mold to be used, the use of lower over-mold 174 is preferred because the weight of the disposer would not tend to peel the container cover 120 away from the mold.
[0030] The container covers 120 of FIGS. 4 A-B are shown with an annular rim 128 formed close to the periphery of the container cover 120 . The rim 128 is formed where the cover 120 engages the lip ( 12 in FIG. 2) of the container body and assists in sealing the cover 120 thereto. In another modification, and as best shown in FIG. 3D, the lower over-mold 174 of the molded portion 170 can have an optional seal 176 integrally formed about its periphery. The peripheral seal 176 can also be used to seal the attachment of the container cover 120 and lip 12 (FIG. 2) of the container body. A preferred arrangement of the optional seal 176 is shown in the cross-section of FIG. 5. The optional seal 176 preferably extends from the tapering lower-over mold 174 to the edge 122 of the container cover 120 and preferably has a thickness of approximately 0.01-inch. In addition, the optional seal 176 preferably has three annular rims 178 formed thereon for engaging the lip 12 (FIG. 2).
[0031] As best shown in FIG. 3A, the upper over-mold 172 preferably has an outer radial dimension greater than that of the gasket portion 130 and almost as great as the top container cover 120 . In one example, the upper over-mold 172 can have an outside diameter d 3 of approximately 5¼-inches for a container cover 120 having an outside diameter d 4 of approximately 6-inches. The upper over-mold 172 has a preferable maximum height h 3 of approximately {fraction (1/8)}-inch. The lower over-mold 174 (FIG. 3D) has a similar outside diameter.
[0032] The lower over-mold 174 can absorb impact noises created by food in the grinding chamber as well as diminish vibration. As best shown in FIG. 2, the lower over-mold 174 preferably has a height, e.g., height h 4 approximately {fraction (1/4)}-inch, which preferably is greater than the height of the upper over-mold 172 . Furthermore, the lower over-mold 174 preferably tapers from its central region on the gasket 100 towards its outside diameter. Similarly, the upper over-mold 172 also preferably tapers from its central region on the gasket 100 towards its outside diameter.
[0033] The disclosed vibration isolation gasket 100 provides a flexible coupling between the disposer and the sink 30 that can reduce the transmission of the vibration to the sink, and accordingly reduce the noise at the sink and surrounding areas. Vibration isolation occurs primarily at the sleeve portion 150 . When installed, the sleeve portion 150 is in tension due to the weight of the disposer, which can be as high as 20 pounds, but this amount of tension is relatively low given the composition and dimensions for the sleeve portion 150 . Consequently, the sleeve portion 150 is still flexible under the tensile load and is able to absorb the vibration of the disposer caused by the motor and the impacting of food waste. Moreover, and in contradistinction to the prior art illustrated in FIG. 1, no hard metallic components akin to the housing collar 24 are present within or coupled to the gasket 100 to undesirably couple vibrations from the cover 120 to the support flange 70 and/or other structural components coupled to the sink. In addition, the over-molded portion 170 of disclosed gasket 100 also dampens vibration of the housing top, adding additional novelty when compared with the prior art illustrated in FIG. 1.
[0034] Vibration in a disposer typically has a broad spectrum, and therefore the disclosed gasket 100 is preferably effective in isolating disposer vibrations over a wide frequency range. The disclosed gasket 100 has been shown through testing to be effective in reducing vibratory noise in a frequency range from 80 to 1000 Hz. These test results are shown in FIGS. 5 A-B, and compare vibration and acoustic spectrums of a disposer having a conventional mounting gasket with a disposer having the vibration isolation gasket of the present disclosure.
[0035] Referring to FIG. 6A, sink vibration spectrum 202 is plotted for a 1-hp disposer rigidly mounted to a sink in the conventional manner, while sink vibration spectrum 204 is plotted for a 1-hp disposer mounted to the sink with the disclosed vibration isolation gasket of the present disclosure. The rigidly mounted disposer in spectrum 202 has a spectrum total of approximately 45.5-m/sec 2 , while the disposer mounted with the disclosed gasket of the present disclosure in spectrum 204 has a spectrum total of approximately 15.3-m/sec 2 . Consequently, the disclosed gasket reduces the transfer of the disposer's vibration to the sink by as much as a third. As evidenced in the spectrum 204 , the disclosed gasket 100 is particularly effective in reducing the transmission of vibration in the frequency range of about 200 to 650 Hz.
[0036] In FIG. 6B, acoustic spectrums 212 and 214 illustrate the relative level of structural noise produced when the two mounting gaskets are used. A first acoustic spectrum 212 is plotted for the 1-hp disposer rigidly mounted to the sink in the conventional manner, and a second acoustic spectrum 214 is plotted for the 1-hp disposer mounted to the sink with the disclosed vibration isolation gasket of the present disclosure. As a result of the improved vibration isolation, the disclosed gasket produced less noise (spectrum 214 ) when compared to the conventional gasket arrangement (spectrum 212 ).
[0037] [0037]FIG. 7 discloses yet another embodiment of a vibration isolation gasket 100 , which is illustrated in a perspective view. Those components that are similar in structure and function to the gasket described earlier are similarly numbered and are not repeated here. In contrast to previous embodiments, the gasket portion 130 of the present embodiment, while still molded to the container cover 120 , does not include a plurality of pleats formed in the opening 136 . Instead, the isolation gasket 100 of FIG. 7 includes a secondary baffle 140 that can be mounted in the drain opening (not shown) above the gasket portion 130 . The secondary baffle 140 can be similar to those disclosed in U.S. patent application Ser. No. 10/066,893, filed Feb. 4, 2002 and entitled “Baffle for a Food Waste Disposer to Reduce Noise and Associated Methods,” which is incorporated herein by reference in its entirety.
[0038] The secondary baffle 140 has an annular body 142 , which can have a recessed rim 144 for engaging a complimentary rib formed on the drain opening (not shown). A plurality of pleats 147 are formed in an opening 146 though the secondary baffle 140 , which as in earlier embodiments reduces noise transmitted through the opening and prevents food waste from escaping. When the disclosed gasket 100 of FIG. 7 is installed on the drain opening, the bottom of the secondary baffle 140 preferably tightly fits into the drain opening and is positioned to rest on an annular surface or shoulder 138 of the gasket portion 130 . So configured, the secondary baffle 140 allows a user to readily clean or replace the secondary baffle 140 if needed without having to remove the mounting gasket and/or otherwise disassemble or disconnect the disposer from under the sink. Because the pleats 147 in the baffle 140 are relatively thin and subject to wear and tear, this embodiment is believed particularly user-friendly.
[0039] In contrast to prior art solutions, the disclosed over-molded vibration isolation gasket does not considerably increase the distance between the disposer and the sink, which might otherwise require a number of modifications to the plumbing to be connected to the disposer. Furthermore, the disclosed over-molded vibration isolation gasket minimizes the number of mechanical couplings needed to install the disposer, which reduces the possibility of an improper installation. Moreover, manufacturing of the disposer is simplified because the mounting gasket and container cover are integrated into a single piece. Other benefits are evident to those of ordinary skill in the art.
[0040] The foregoing description of preferred and other embodiments is not intended to limit or restrict the scope or applicability of the inventive concepts conceived of by the Applicants or defined in the appended claims. In exchange for disclosing the inventive concepts contained herein, the Applicants desire all patent rights afforded by the appended claims. It is intended that the inventions defined by the appended claims include all modifications and alterations to the full extent that such modifications or alterations come within the scope of the appended claims or the equivalents thereof. | Disclosed herein is a vibration isolation gasket for mounting a food waste disposer to a sink that is at least partially molded onto a portion of the housing of the disposer, and preferably to the disposer's container cover. The vibration isolation gasket preferably includes a rubberized and integrally-formed gasket portion, sleeve portion, and over-molded portion. The gasket portion couples to the drain opening and may contain pleats to prevent food ejection from the disposer. The sleeve portion connects the gasket and over-molded portions, bears the weight of the disposer as it hangs from the sink, and acts as the primary structure for reducing vibration-induced noise. The over-molded portion is preferably molded onto the top and bottom of the container cover, which is in turns crimped to the remainder of the disposer housing. | 4 |
CROSS REFERENCE TO RELATED APPLICATIONS
This application includes subject matter related to the co-pending application entitled: "RADIAL AND PRUNED RADIAL INTERPOLATION", the co-pending patent application Ser. No. 08/990,016 entitled: "COMMON PRUNED RADIAL AND PRUNED TETRAHEDRAL INTERPOLATION HARDWARE IMPLEMENTATION", the co-pending patent application Ser. No. 08/989,962 entitled "NON-SYMMETRIC RADIAL AND PRUNED RADIAL INTERPOLATION", the co-pending patent application Ser. No. 08/990,000 entitled: "NON-SYMMETRIC TETRAHEDRAL AND PRUNED TETRAHEDRAL INTERPOLATION", and the co-pending patent application Ser. No. 08/989,998 entitled "COMMON NON-SYMMETRIC PRUNED RADIAL AND NON-SYMMETRIC PRUNED TETRAHEDRAL INTERPOLATION HARDWARE IMPLEMENTATION", each incorporated by reference herein and filed on even date herewith.
FIELD OF THE INVENTION
This invention relates to the transformation of data, and more particularly to the transformation of data from a first space to a second space, such as in the conversion from a first color space to a second color space.
BACKGROUND OF THE INVENTION
Colorimetry has long been recognized as a complex science. In general, it has been found possible and convenient to represent color stimuli vectors in a three-dimensional space, called tristimulus space. Essentially, as defined in 1931 by the Commission Internationale L'Eclairage (CIE), three primary colors (X, Y, Z) can be combined to define all light sensations we experience with our eyes (that is, the color matching properties of an ideal trichromatic observer defined by specifying three independent functions of wavelength that are identified with the ideal observer's color matching functions form an international standard for specifying color). The fundamentals of such three-dimensional constructs are discussed in the literature, such as Principles of Color Technology, by Billmeyer and Saltzman, published by John Wiley & Sons, Inc., NY, copyright 1981 (2nd. ed.) and Color Science: Concepts and Methods, Quantitative Data and Formulae, by Wyszecki and Stiles, published John Wiley & Sons, Inc., copyright 1982 (2d ed.), incorporated herein by reference in pertinent parts, particularly pages 119-130.
Trichromatic model systems--such as red, green, blue (RGB); cyan, magenta, yellow (CMY); hue, saturation, value (HSV); hue, lightness, saturation (HLS); luminance, red-yellow scale, green-blue scale (La*b*); luminance, red-green scale, yellow-blue scale (Luv); YIQ used in commercial color television broadcasting; and the like--provide alternatives for the system designer. See such works as Fundamentals of Interactive Computer Graphics, by Foley and Van Dam, Addison-Wesley Publishing Company, incorporated herein by reference in pertinent parts, particularly pages 606-621, describing a variety of tri-variable color models.
Color transformation between model systems in digital data processing presents many problems to the original equipment manufacturer. The translation of data from one system to another system is difficult because the relationship between the systems are generally non-linear. Therefore, a crucial problem is the maintaining of color integrity between an original image from an input device (such as a color scanner, CRT display, digital camera, computer software/firmware generation, and the like) and a translated copy at an output device (such as a CRT display, color laser printer, color ink-jet printer, and the like).
For example, computer artists want the ability to create a color image on a computer video and have a printer provide the same color in hard copy. Or, an original color photograph may be digitized with a scanner; resultant data may be transformed for display on a video monitor or reproduced as a hard copy by a laser, ink-jet or thermal transfer printer. As discussed in the reference materials cited, colors can be constructed as renderings of the additive primary colors, red, green, and blue (RGB), or of the subtractive primary colors, cyan, magenta, yellow and black (CMYK). A transformation may require going from an RGB color space, for example, a computer video monitor, to a CMYK color space, for example, a laser printer hard copy. A transformation from one color space to another requires complex, non-linear computations in multiple dimensions. Some transform operations could be accomplished through matrix multiplication
However, a difficulty in this method of color space conversion results from imperfections in the dyes, phosphors, and toners used for the production of the colors. An additional complication is that different types of media produce different color responses from printing with the same mixes of colorants. As a result, a purely mathematical color space conversion method does not provide acceptable color reproduction.
It has been recognized that superior results in color space conversion are obtained using a look up table scheme based upon a set of empirically derived values. Typically the RGB color space used for video displays use eight bits to represent each of the primary colors, red, green, and blue. Therefore, twenty four bits are required to represent each picture element. With this resolution, the RGB color space would consist of 2 24 or 16,777,216 colors. Performing a color space conversion from each of these points in the RGB color space to generate the four CMYK (to maintain black color purity in printing, a separate black is usually provided rather than printing with all three of cyan, magenta, and yellow colorants to generate what is commonly known as process black) color space components would require a look-up table with 4×2 24 or 67,108,864 bytes of data. The empirical construction of a look-up table with this number of entries is too costly.
In making the transform from one color space to another, a number of interpolation schemes well known in the field of color space conversion may be employed. Methods of performing color space conversion using trilinear interpolation, prism interpolation, and tetrahedral interpolation are disclosed in the published article PERFORMING COLOR SPACE CONVERSIONS WITH THREE DIMENSIONAL LINEAR INTERPOLATION, JOURNAL OF ELECTRONIC IMAGING, July 1995 Vol. 4(3), the disclosure of which is incorporated herein by reference. U.S. Pat. No.3,893,166 (the disclosure of which is incorporated herein by reference), issued to Pugsley, discloses a scheme for translation between color spaces which uses a look-up table to access values used in an interpolation.
Conversion of large amounts of data between color spaces, such as is required for color printing, is a time consuming operation using the prior art methods of interpolation. The use of the computationally intensive prior art methods of interpolation for the color space conversion process makes high rates of data throughput difficult to achieve. A need exists for an interpolation method and interpolation apparatus that will enable a reduction in the computations required for performing a conversion between color spaces.
SUMMARY OF THE INVENTION
Accordingly, a pruned tetrahedral interpolator for interpolating between interpolation data values uses input data values each having d components to generate output data values. The d components are represented by d sets of bits each partitioned to form d sets of higher order bits and d sets of lower order bits. The d sets of higher order bits are used for selecting 2 d of the interpolation data values. The pruned tetrahedral interpolator includes a first multiplexer having a first multiplexer output and a first control input. The first multiplexer is configured for receiving the 2 d of the interpolation data values. The first control input is configured for receiving a first value determined from the d sets of lower order bits. The pruned tetrahedral interpolator further includes a first adder having a first input, a second input, and an output. The first input is coupled to the first multiplexer output and the second input is configured to receive one of the 2 d of the interpolation data values.
A tetrahedral interpolator for interpolating between interpolation data values uses input data values each having d components to generate output data values. The d components are represented, correspondingly, by d sets of bits each partitioned to form d sets of higher order bits and d sets of lower order bits. The d sets of higher order bits are used forelecting 2 d of the interpolation data values. The tetrahedral interpolator includes a set of 2×2 d multiplexers with each of the multiplexers having a multiplexer output and configured to receive the 2 d of the interpolation data values. Each of the multiplexers is used for selecting a one of the 2 d of the interpolation data values responsive to one of 2×2 d values determined from the d sets of lower order bits. The tetrahedral interpolator further includes a set of 2 d adders with each of the adders having a first input, a second input, and an output. Each of a first group of 2 d of the multiplexers have the corresponding of the multiplexer output coupled to one of the first input. Each of a second group of 2 d of the multiplexers have the corresponding of the multiplexer output coupled to one of the second input. The set of 2×2 d multiplexers and the set of 2 d adders form a stage.
A method of tetrahedral interpolation uses interpolation data values for selection using input data values each having d components. The d components are represented by d sets of bits each partitioned to form d sets of higher order bits and d sets of lower order bits with each of the d sets of lower order bits having n bits. The d sets of lower order bits are designated as 1b 1 , 1b 2 , . . . , 1b d with the bit position of each bit of the d sets of lower order bits designated from the most significant of the lower order bits to the least significant of the lower order bits by a value of i ranging, correspondingly, from n-1 to 0. The method of tetrahedral interpolation includes the step of computing a first value according to v[i]=2 d-1 ×1b 1 [i]+2 d-2 ×1b 2 [i]+ . . . +2 d-d ×1b d [i] for the value of i equal to (n-1). The method of tetrahedral interpolation further includes the step of computing a first set of AND values according to v[n-1] & k, for the value of k ranging from 2 d -1 to 0. The method of tetrahedral interpolation further includes the step of computing a first set of OR values according to v[n-1]|k, for the value of k ranging from 2 d -1 to 0. The method of tetrahedral interpolation further includes the step of selecting a first set of 2 d pairs of the interpolation data values using the first set of the AND values and the first set of the OR values. Each of the first set of 2 d pairs are selected using one of the first set of the AND values and one of the first set of the OR values each computed using the same of the value of k. The method of tetrahedral interpolation further includes the step of computing a first set of 2 d sums by summing each of the first set of 2 d pairs of the interpolation data values.
A method of pruned tetrahedral interpolation uses interpolation data values for selection using input data values each having d components. The d components are represented by d sets of bits each partitioned to form d sets of higher order bits and d sets of lower order bits with each of the d sets of lower order bits having n bits. The d sets of lower order bits are designated as 1b 1 , 1b 2 , . . . , 1b d with the bit position of each bit of the d sets of lower order bits designated from the most significant of the lower order bits to the least significant of the lower order bits by a value of i ranging, correspondingly, from n-1 to 0. The method of pruned tetrahedral interpolation includes a step of computing a first set of 2 n -2 values using bitwise AND operations and bitwise OR operations operating upon v[i]. Where v[i] is equal to 2 d-1 ×1b 1 [i]+2 d-2 ×1b 2 [i]+ . . . +2 d-d ×1b d [i] for the value of i ranging from (n-1) to 0. The method of pruned tetrahedral interpolation further includes a step of selecting at least the minimum of 2 n and 2 d of the interpolation data values using ones of the first set of 2 n -2 values, v[i] for one of the values of i equal n-1, and the d sets of higher order bits. The method of pruned tetrahedral interpolation further includes a step of adding a second set of the interpolation data values formed from the interpolation data values from the step of selecting to generate a sum.
A pruned tetrahedral interpolator for interpolating between interpolation data values uses input data values each having d components to generate output data values. The d components are represented by d sets of bits partitioned to form d sets of lower order bits with each of the d sets of lower order bits having n of the bits. The pruned tetrahedral interpolator includes a first set of 2 n -1 multiplexers each configured for receiving one of a set of control inputs and having a multiplexer output. Each of the multiplexers of the first set for selecting from the interpolation data values is responsive to the one of the set of control inputs. The pruned tetrahedral interpolator further includes a means for adding configured for receiving the multiplexer output of the set of multiplexers.
DESCRIPTION OF THE DRAWINGS
A more thorough understanding of the invention may be had from the consideration of the following detailed description taken in conjunction with the accompanying drawings in which:
FIG. 1a is a representation of output color space values used for interpolation in a cubic lattice. The vertices of the each of the cubes forming the cubic lattice represent values of the output color space.
FIG. 1b is a graphical representation of a color space conversion process from a color expressed in a cylindrical coordinate to a color expressed in a rectangular coordinate.
FIGS. 2a through 2d are a graphical representation of the selection of a single sub-cube using the corresponding bits from the lower order bits of the input color space value.
FIGS. 3a through 3h show the eight possible sub-cubes which can be selected from a cube using the corresponding bits from the lower order bits of the input color space value.
FIG. 4 shows the numbering of the vertices of the cube for the purposes of selecting the sub-cube containing the result of the interpolation using the corresponding bits of the lower order bits.
FIG. 5 is a graphical representation of the radial sub-cube generation process.
FIG. 6a through 6e shows a graphical representation of multiple iterations of the cube subdivision process used in radial interpolation.
FIG. 7 shows a hardware implementation of a radial interpolator.
FIG. 8 is a high level flow diagram of a generalized method for performing radial interpolation.
FIG. 9 is a diagrammatic representation of the computations required for generation of the sub-cubes in pruned radial interpolation.
FIG. 10 shows a hardware implementation of pruned radial interpolation.
FIG. 11 is a high level flow diagram of a generalized method for performing pruned radial interpolation.
FIG. 12 is a high level flow diagram of a method implemented in software for performing pruned radial interpolation.
FIG. 13 is a representation of the outer bounds of a CMY and a RGB color space showing the colors at the outer bounds of the color spaces.
FIG. 14 is a graphical representation of the generation of a sub-cube from two tetrahedrons.
FIG. 15 is a diagrammatic representation of the computations required for generation of the sub-cubes in pruned tetrahedral interpolation.
FIG. 16 is a high level flow diagram of a generalized method for performing tetrahedral interpolation.
FIG. 17 shows a hardware implementation of tetrahedral interpolation.
FIG. 18 shows a hardware implementation of pruned tetrahedral interpolation.
FIG. 19 is a high level flow diagram of a generalized method for performing pruned tetrahedral interpolation.
FIG. 20 is a high level flow diagram of a method for implement in software for performing pruned tetrahedral interpolation.
FIG. 21 is a diagrammatic representation of a common radial interpolation and pruned tetrahedral interpolation implementation.
FIG. 22 shows a hardware implementation of common pruned radial and pruned tetrahedral interpolation.
FIG. 23a through 23e shows a graphical representation of a non-symmetric interpolation process.
FIG. 24 shows a graphical representation of the generation of a sub-cube from a cube using non-symmetric sub-cube generation.
FIG. 25 is a diagrammatic representation of the non-symmetric radial interpolation process.
FIG. 26 is a high level flow diagram of a method for performing non-symmetric radial interpolation.
FIG. 27 is a high level flow diagram of a method implemented in software for performing non-symmetric pruned radial interpolation.
FIG. 28 shows a hardware implementation of non-symmetric pruned radial interpolation.
FIG. 29 is a high level flow diagram of a generalized method for performing non-symmetric radial interpolation.
FIGS. 30a and 30b show a hardware implementation of non-symmetric radial interpolation.
FIG. 31 is a diagrammatic representation of the non-symmetric pruned tetrahedral interpolation process.
FIG. 32 shows a high level flow diagram of a method for performing non-symmetric pruned tetrahedral interpolation.
FIG. 33 is a high level flow diagram of a method implemented in software to perform non-symmetric pruned tetrahedral interpolation.
FIG. 34 shows a hardware implementation of non-symmetric pruned tetrahedral interpolation.
FIG. 35 is a high level flow diagram of a generalized method for implementing non-symmetric tetrahedral interpolation.
FIGS. 36a, and 36b show a hardware implementation of a non-symmetric tetrahedral interpolator.
FIGS. 37a, 37b, and 37c show a hardware implementation of a common non-symmetric pruned radial and non-symmetric pruned tetrahedral interpolator.
FIG. 38 includes a C code listing of a method for implementing pruned radial interpolation in software.
FIG. 39 includes a VHDL listing used for generating a hardware implementation of pruned radial interpolation.
FIG. 40 includes a C code listing of a method for implementing pruned tetrahedral interpolation in software.
FIG. 41 includes a VHDL listing used for generating a hardware implementation of pruned tetrahedral interpolation.
FIG. 42 includes a VHDL listing used for generating a hardware implementation of common pruned radial interpolation and pruned tetrahedral interpolation.
FIG. 43 includes a C code listing of a method for implementing non-symmetric pruned radial interpolation in software.
FIG. 44 includes a VHDL listing used for generating a hardware implementation of non-symmetric pruned radial interpolation.
FIG. 45 includes a C code listing of a method for implementing non-symmetric pruned tetrahedral interpolation in software.
FIG. 46 includes a VHDL listing used for generating a hardware implementation of non-symmetric pruned tetrahedral interpolation.
FIG. 47 includes a VHDL listing used for generating a hardware implementation of common non-symmetric pruned radial and non-symmetric pruned tetrahedral interpolation.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
The present invention is not limited to the specific exemplary embodiments illustrated herein. In addition, although several embodiments of sub-cube interpolation will be discussed in the context of a color laser printer, one of ordinary skill in the art will recognize after understanding this specification that the disclosed embodiments of sub-cube interpolation have applicability in any interpolative data transformation between spaces. For example, the interpolations required for the rendering of three dimensional graphics could advantageously use the disclosed interpolation techniques.
Sub-cube interpolation using tetrahedral interpolation to generate each of the vertices of the successive sub-cubes is taught in the co-pending application having U.S. patent application Ser. No. 08/504,406, the disclosure of which is incorporated by reference herein. However, the method for generation of the sub-cube vertex values disclosed in this co-pending application requires a large number of computations. A need exists for a method of generating the sub-cube vertex values which is more computationally efficient.
Shown in FIG. 1a is a cubic lattice 1. The cubic lattice is formed of a multiplicity of cubes with the vertices of the cubes representing values in the output color space. The input color space values are each partitioned into an upper portion and a lower portion. The upper portion of each of the input color space values serves as an index to address the vertex values of the cubic lattice 1 used for interpolation. The lower portion of each of the input color space values is used to interpolate between the output color space values accessed using the upper portion of the input color space value. Each of the dimensions of the cubic lattice 1 correspond to one of the components of the input color space value. The values associated with the vertices of cubic lattice 1 are used to generate output color space values.
Each of the output color space values has multiple components corresponding to the dimensions of the output color space. Conversion is done from the input color space values to components of the output color space values. Conversion to each output color space value component uses a distinct set of vertex values. For the case in which there are three components to each of the output color space values, there are three sets of vertex values used for the color space conversion. For this case, it would be possible to regard each vertex value as formed of three values with each of the three values selected from one of the three sets. Viewing the vertex values in this way, the conversion to each of the components of the output color space values would be performed in parallel. It is also possible to perform the conversion to each of the output color space components serially. Done in this manner, the conversion can be viewed as using three separate cubic lattices, one corresponding to each set of vertex values.
Shown in FIG. 1b is a general graphical representation of the interpolation process. Consider, for example the conversion of an input color space value (a, b, c) 10, representing a color in a cylindrical color space, to an output color space value (x, y, z) 11 representing that same color in a Cartesian color space. In this example, each of a, b, and c are represented by eight bits. Each of the three groups of eight bits can be partitioned, for example, into four upper bits 10a (represented by a u , b u , and c u ) and four lower bits 10b (represented by a l , b l , and c l ). The three groups of four upper bits 10a are used as an index into the cubic lattice 1 to retrieve the eight values corresponding to the vertices of a cube within the cubic lattice 1 that will be used as interpolation data values. The three groups of four lower bits 10b are then used to interpolate between the eight interpolation data values corresponding to the vertices of the cubic lattice 1 to generate a component of the the output color space value 11.
One of ordinary skill in the art will recognize that other partitions of the bits of the input color space value 10 are possible. The particular partition of the bits will depend upon such things as the size of the memory available to store the values of the output color space used for the interpolation and the amount of change in the output color space value that occurs between vertices of cubic lattice 1. A tradeoff exists between the accuracy of the interpolation and the size of the memory used to store the out put color space values used as the interpolation data values. If the characteristics of the output color space are such that it changes relatively linearly throughout the color space, then fewer vertices in cubic lattice 1 are necessary to deliver an acceptable level of interpolation accuracy.
The index formed by a u , b u , and c u serves as an entry point into the cubic lattice. The index addresses one vertex of the eight vertices of the cube used as the interpolation data values. Each of the vertices of the cube corresponds to a value used for interpolating to generate one component of the output color space value 11. The eight associated vertices of a cube in the cubic lattice 1 have the following relative addresses:
(a u , b u , c u )
(a u , +1, b u , c u )
(a u , b u , +1, c u )
(a u , b u , c u +1)
(a u , +1, b u +1, c u )
(a u , b u , +1, c u +1)
(a u , +1, b u +1, c u +1)
The cube subdivision interpolation method disclosed in the United States patent application having U.S. patent application Ser. No. 08/504,406, performs an interpolation by generating a sub-cube using the values associated with the vertices of the previously generated sub-cube. The initial cube formed by the vertex values associated with the three groups of upper order bits (a u , b u , c u ) 10a is used to generate the first sub-cube. This initial cube can be divided into eight sub-cubes. The three groups of lower order bits 10b (a 1 , b 1 , c 1 ) are used to select one of the eight possible sub-cubes formed for the next iteration of sub-cube division. These three groups of lower order bits 10b identify in which of the eight possible sub-cubes the result of the interpolation will be located. When the sub-cube which contains the result of the interpolation is identified, this sub-cube is used to generate the next sub-cube which contains the result of the interpolation. This process is successively repeated until the last sub-cube containing the result of the interpolation is generated. One of the values associated with a vertex of this last sub-cube generated is used as the result of the interpolation.
FIG. 2a through 2d graphically represent the selection of a sub-cube using the three groups of lower order bits 10b (a 1 , b 1 , c 1 ). For purposes of explaining the sub-cube selection, consider the case in which the lower order bits 10b for each component of the input color space value consists of four bits. Shown in each of FIGS. 2a through 2d are the axes corresponding to the a, b, and c components of the input color space value. Each of these axes corresponds to a dimension of the input color space. Sub-cubes are designated using one corresponding bit (corresponding in the sense that they are coefficients of the same power of 2) from the lower order bits 10b of each component of the input color space value. Each bit position of the lower order bits 10b of each component can be viewed as dividing the cube in half along the dimension corresponding to the component. The value of the bit for each component determines which half of the cube is selected in the corresponding dimension, for the purpose of determining in which sub-cube the result of the interpolation is located. The selected sub-cube will be the volume defined by the intersection of the cube halves selected by the corresponding bits of each component of the lower order bits 10b of the input color space value. If the bit of the lower order bits 10b for the component is a "1", a corner of the selected cube half is displaced one half the length along the corresponding axis from the origin of the cube. If the bit of the component is a "0", the corner of the selected cube half includes the origin of the cube. Shown in FIGS. 3a through 3h are the eight possible sub-cubes defined by the common intersection of the cube halves designated by the corresponding bit from each of a 1 , b 1 , and c 1 .
By numbering the vertices of the cubes in a manner that is consistent with the assignment of the groups of lower order bits 10b of the components of the input color space value to the axes, the vertex of the cube used to generate the sub-cube associated with a vertex of the sub-cube to be generated, is designated by the binary value formed by combining the corresponding bits from each of the groups of lower order bits 10b of the components. Shown in FIG. 4 is a cube with the axes labeled and with the vertices numbered. The cube used to generate a sub-cube and the generated sub-cube share a vertex. With this assignment of vertex numbers, the number of the vertex of the cube used to generate the sub-cube which is included within the sub-cube generated is the binary value formed from the corresponding bits of a 1 , b 1 , and c 1 , for a given bit position.
An example will be explained to illustrate the interpolation using the sub-cube generation. Assume that the following values are used for a 1 , b 1 , and c 1 :
TABLE 1______________________________________ a.sub.1 = 1010 b.sub.1 = 1110 c.sub.1 = 0011______________________________________
With these values assigned to a 1 , b 1 , and c 1 , the vertex number 6 (computed by selecting the most significant bit from each of a 1 , b 1 , and c 1 and concatenating these into a binary value) of the cube used to generate the first sub-cube is also a vertex of the first sub-cube. The vertex of the first sub-cube included within the second sub-cube generated is vertex number 2 (computed by selecting the second most significant bit from each of a 1 , b 1 , and c 1 and concatenating these into a binary value). The vertex of the second sub-cube included with the third sub-cube generated is vertex number 7 (computed by selecting the third most significant bit from each of a 1 , b 1 , and c 1 and concatenating these into a binary value). The vertex of the third sub-cube included with the fourth sub-cube generated is vertex number 1 (computed by selecting the fourth most significant bit from each of a 1 , b 1 , and c 1 and concatenating these into a binary value). The vertex values of the first sub-cube are generated with the vertex values accessed using the upper order bits (a u , b u , c u ) 10a of the components of the input color space value. The vertex values of the second sub-cube are generated using the vertex values generated for the first sub-cube. The vertex values of the third sub-cube are generated using the vertex values generated for the second sub-cube. Finally, the vertex values of the fourth sub-cube are generated using the vertex values generated for the third sub-cube. In sub-cube interpolation, the value associated with the vertex numbered 0 of the final sub-cube generated is the value used as the result of the interpolation. This result is one component of the output color space value. This sub-cube generation procedure could be applied with an arbitrary number of bits used to specify each component of the lower order bits 10b of the input color space value.
A variety of methods have been previously employed for the generation of the sub-cube values. These methods include tetrahedral, pyramid, PRISM, and Trilinear. Radial sub-cube generation is a new method of sub-cube generation which achieves a substantial reduction in the computational complexity required to generate the sub-cubes. It should be recognized that each interpolation method can generate different results because the interpolation process is an approximation of the color space conversion. Depending upon the location in the color space where the conversion is performed and the preferred characteristics of the result, one method may yield more desirable results than another.
Shown in FIG. 5 is a graphical representation of the radial sub-cube generation method. Clearly explaining the radial sub-cube generation process requires some notational definition. As was previously the case, a 1 , b 1 , and c 1 designate the lower order bits 10b of the respective a, b, and c components of input color space value. The value of the variable i will be used to designate the bit position within the lower order bits 10b (a 1 , b 1 , c 1 ), as shown below, for the case in which four bits are used to designate each component of the lower order bits 10b. The maximum value of i (a value of 3) corresponds to the most significant bit position of the lower order bits 10b. The minimum value of i (a value of 0) corresponds to the least significant bit position of the lower order bits 10b. As one of ordinary skill in the art will recognize, this notation is easily adapted for a different number of bits used for each component of the lower order bits 10b. For n bits used to represent the lower order bits 10b, the value of i ranges from n-1 to 0.
TABLE 2______________________________________i: 3 2 1 0______________________________________a.sub.1 : 1 0 1 0b.sub.1 : 1 1 1 0c.sub.1 : 0 0 1 1______________________________________
Using this notation, the value of i indirectly indicates the iteration of the sub-cube generation. A value of i equal to 3, corresponds to generation of the first sub-cube. This first sub-cube includes vertex number 6 from the cube formed by accessing the values of cubic lattice 1 using the upper order bits 10a. For the value of i equal to 0, the fourth sub-cube is generated. This fourth sub-cube includes vertex number 1 from the third sub-cube generated. To determine the vertex number of the cube used to generate the sub-cube which is included within the sub-cube, the following equation is used:
v(i)=4a.sub.1 (i)+2b.sub.1 (i)+c.sub.1 (i) eqn. 1a
In equation 1a, v(i) represents the vertex number of the cube included within the generated sub-cube. Each of the a 1 (i), b 1 (i), and c 1 (i) represents the binary value associated with the "ith" position in the respective component of the lower order bits 10b. For each value of i, equation 1a yields the correct number of the vertex of the cube used to generate the sub-cube which will be included within the desired sub-cube. The values which i may assume include the integers from n-1 to 0 inclusive, where n is the number of bits used to specify each of the components of the lower order bits 10b of the input color space value. The value of the vertex having the number v(i) is designated by P[v(i)]. Equation 1a can be generalized for input color space value 10 formed from d components. Given below is a generalized expression for v[i]:
v[i]=2.sup.d-1 ×1b.sub.1 [i]+2.sup.d-2 ×1b.sub.2 [i]+2.sup.d-3 ×1b.sub.3 [i]+ . . . +2.sup.d-d ×1b.sub.d [i] eqn. 1b
In equation 1b, each of the "1b" represent the lower order bits 10b one of the d components of the input color space value 10. As in equation 1a, the values of i include the integers from n-1 to 0 inclusive.
The values associated with the eight vertices of the sub-cube are generated from the cube as shown in table 3. Those vertex values designated by P'[sub-cube vertex number] represent sub-cube vertex values and those vertex values designated by P [cube vertex number] represent the vertex values of the cube used to generate the sub-cube vertex values. A given value of a sub-cube vertex is generated by averaging the corresponding vertex value of the cube from which the sub-cube is generated with the value of the vertex of the cube used to generate the sub-cube included within the sub-cube (this is the value designated by P[v(i)].
TABLE 3______________________________________ P'[7] = (P[7] + P[v(i)])÷2 P'[6] = (P[6] + P[v(i)])÷2 P'[5] = (P[5] + P[v(i)])÷2 P'[4] = (P[4] + P[v(i)])÷2 P'[3] = (P[3] + P[v(i)])÷2 P'[2] = (P[2] + P[v(i)])÷2 P'[1] = (P[1] + P[v(i)])÷2 P'[0] = (P[0] + P[v(i)])÷2______________________________________
Shown in FIG. 6a through FIG. 6e is a graphical representation of multiple iterations of the sub-cube division process used in radial interpolation. The values used for the components of the lower order bits 10b of the input color space value in the example of FIG. 6 are the same as those shown in Table 2. The values of the vertices of the cube used for generation of the first sub-cube (these values are accessed using the higher order bits 10a of the input color space value) are loaded from a color table stored in memory. After the final iteration of sub-cube division, vertex number 0 of the final sub-cube is used as the result of the interpolation process. To prevent the accumulation of rounding errors during the actual computation of the sub-cube vertex values, the required division by 2 for each iteration of sub-cube generation is performed only on the values of the vertices of the final sub-cube generated. When the division is performed in this manner, the divisor used is 2 n , where n is the number of bits assigned to each component of the lower order bits 10b. Division by 2 n can be performed easily by performing a right shift operation. For the case in which n=4, this divisor is 16. With the division operation not performed until after the generation of the final sub-cube vertex values, the sub-cube generation process reduces to a series of additions of selected vertex values of the generated sub-cubes.
Shown in FIG. 7 is a hardware implementation of a radial interpolator 100. In addition, FIG. 7 illustrates the progression of the radial interpolation through radial interpolator 100 using values for v[i] corresponding to lower order bits 10b of table 2. Each of the values (P[0] through P[7]) associated with the eight vertices selected using upper order bits 10a is coupled to a multiplexer input of first multiplexer 101. The value of v[i], for i equal to 3, is coupled to the control input of first multiplexer 101. The value of v[i], for i equal to 3, is used to select the value associated with the vertex of the cube selected using upper order bits 10a that will be included in the first sub-cube generated. The output of first multiplexer 101 is coupled to a first input of each adder of a first set of adders 102 composed of eight adders. The second input of each adder of the first set of adders 102 is coupled to one of the values selected using upper order bits 10a. First multiplexer 101 and first set of adders 102 form a first stage of radial interpolator 100. It can be seen, that with this configuration of multiplexer 101 and first set of adders 102, the averaging operations of table 3 (without the division by two, which, as previously mentioned, is delayed until all the iterations of radial interpolation are completed) for a single iteration of radial interpolation are completed. A second, third, and fourth stage of radial interpolator 100 are formed from, respectively, a second multiplexer 103 and second set of adders 104, a third multiplexer 105 and third set of adders 106, and a fourth multiplexer 107 and fourth set of adders 108. The control inputs of the second 103, third 105, and fourth 107 multiplexer inputs are coupled to, respectively, v[i=2], v[i=1], and v[i=0]. The second, third, and fourth stages of radial interpolator perform successive iterations of radial interpolation with each iteration using the relationships of table 3 (again delaying the division by two until completion of all iterations).
Shown in FIG. 8 is high level flow diagram of a method for performing a single iteration of radial interpolation. First, 2 d of interpolation data values are selected 200 using upper order bits 10a. For the case in which the radial interpolation is used for color space conversion, the interpolation data values correspond to vertex values of the selected cube. In addition, for color space conversion d is typically equal to 3, the number of components of the input color space value 10. After vertex values are selected 200, the vertex number of the vertex value required for that iteration is computed 201. For d equals 3, equation 1a is used to compute 201 the required vertex number. Depending on the iteration of radial interpolation, the value of i used to compute v[i] can range from i=3 to i=0. After computation 201 of the vertex number, one of the 2 d of interpolation data values is selected 202 using the computed vertex number. Finally a set of 2 d averages is computed 203 according to the relationships of table 3. To avoid rounding errors the required divisions by 2 for averaging are delayed until all iterations of interpolation are performed.
It was recognized that the number of computations required to perform radial interpolation as shown in FIG. 7 could be substantially reduced. Examination of the radial interpolation process of FIG. 7 reveals that determination of the interpolation result does not require the use of all eight of the vertex values accessed by the upper order bits 10a, nor does it require the use of all the adders shown in FIG. 7. Shown in FIG. 9 is a diagrammatic representation of pruned radial interpolation. FIG. 9 can be understood by working backward from the interpolation result shown in FIG. 7 to determine the values of the vertices (accessed using the upper order bits 10a) that are required to generate the result. As previously mentioned, the value of vertex number 0 (P[0]) of the final sub-cube generated is used as the result of the interpolation. Using the equations listed in table 3 (without the division by 2), the vertices of the sub-cube immediately previous to the final sub-cube that are used to compute the value of vertex number 0 of the final sub-cube can be determined. Similarly, the equations listed in table 3 can be used to determine the vertices of the sub-cube two previous to the final sub-cube that are necessary to compute the needed vertices of the sub-cube immediately previous to the final sub-cube.
This method for determining the vertices of each of the sub-cubes necessary to compute P[0] of the final sub-cube is performed with each value of i from 0 to 3 for the case in which n=4. If this is done, the result shows that the values used to compute P[0] of the final sub-cube consist of only some of the values corresponding to the vertices of the cube accessed by the higher order bits 10a of the input color space value. As a result, only 10 of the 32 adders of FIG. 7 are used for computing a interpolation result from a given input color space value 10. For the values of the lower order bits 10b shown in table 2, the vertex numbers of the cube accessed by the higher order bits 10a to which the values used to compute P[0] of the final sub-cube correspond are: 0, 6, 2, 7, and 1. The values of the vertices of the cube accessed by the higher order bits 10b corresponding to this are: P[0], P[6], P[2], P[7], and P[1]. In general, the values of the vertices of the cube accessed using the higher order bits 10a that are used to compute P[0] of the final sub-cube are P[0], P[v(i=3)], P[v(i=2)], P[v(i=1)], P[v(i=0)]. The general expression which can be derived for n=4 is:
P[0].sub.Final Sub-cube =({8×P[v(i=3)]}+{4×P[v(i=2)]}+{2×P[v(i=1)]}+P[v(i=0)]+P[0])÷16 eqn. 2
Equation 2 is an expression for computing a result using pruned radial interpolation with n=4. A generalized expression for the pruned radial interpolation is: ##EQU1##
Equation 3 can be used to generalize the computation of the pruned radial interpolation result. It should be noted that in equation 2 and the generalized expression in equation 3, the value associated with vertex number 0 of the cube selected using higher order bits 10a is always used. Had the value of a vertex number other than vertex number 0 of the final sub-cube generated been used as the result of the interpolation, the value of that vertex number of the originally selected cube would be used in place of P[0].
The hardware functional blocks required to perform the pruned radial interpolation include adders and multiplexers. With D dimensions in the output color space and n bits representing each group of lower order bits 10b of the input color space value, the requirements of the hardware implementation of the pruned radial interpolation can be computed as:
# of Adders=D×(n+1) eqn. 4
# of Multiplexers=D×n eqn. 5
It should be noted that extra adder specified in equation 4 is used for the purpose of rounding. Additional operations which must be performed by the hardware include multiplication, division, and concatenation. The multiplication and division operations by a power of two can be performed by shifting bit positions. In hardware, this shifting is accomplished by connecting a line corresponding to a bit to a higher order position for multiplication or to a lower order position for division. In hardware, concatenation is accomplished by grouping lines, corresponding to bit positions, together. Therefore, the multiplication, division, and concatenation operations can be performed without the necessity of adding additional hardware.
To generate the gate level design necessary to implement the pruned radial interpolation in hardware, a commonly used hardware description language, such as VHDL, may be used. Included in FIG. 39 is a listing of the VHDL code which can generate a hardware implementation of pruned radial interpolation.
Shown in FIG. 10 is a hardware implementation of a pruned radial interpolator 300 for n equal to 4. It should be noted that the hardware implementation shown in FIG. 10 can be used to generate a single component of the output color space value 11. This same hardware could be used repetitively for an additional (D-1) passes to generate the remaining D-1 components of the output color space value 11. Or, there could be an additional (D-1) replications of the hardware implementation shown in FIG. 10 to generate each of D components simultaneously. Pruned radial interpolator 300 is a hardware implementation of equation 2 without the division by 16. The division by 16 could be accomplished by bit shifting the result of the additions. Selection of four of the five vertex values (P[6], P[2], P[7], and P[l]) used to compute the interpolation result requires four multiplexers 301-304.
The four required additions are accomplished using four adders 305-308. The fifth vertex value required for computation of the interpolation result, P[0], is hard wired into the inputs of one of the adders. It should be noted that because of the associative property of addition, the hardware implementation of FIG. 10 may be implemented so that the additions are performed in a number of different orders. The order shown in FIG. 10 minimizes propagation delay through the adders. Furthermore, other means for adding may be used. For example, a single adder that had a sufficient number of inputs could be used. Or, a microprocessor could be used to accomplish the additions.
The three multiplication operations 309-311 correspond to multiplication by the coefficients 8, 4, and 2 of the first three terms on the right side of equation 2. It should be noted that multiplication operations 309-311 are accomplished in hardware by routing of the lines corresponding to the bit positions on each of the respective multiplexer outputs. Therefore, these multiplications are implemented without additional hardware cost. It is possible to implement the multiplications through the routing of lines because all of the coefficients are powers of 2.
One of ordinary skill in the art will recognize that the hardware implementation shown in FIG. 10 is adaptable for values of n greater than 4 or less than 4. Consider the hardware implementation of a pruned radial interpolator for n equal to 1. This hardware implementation of pruned radial interpolation would be useful for an interpolation which performs a single iteration of cube subdivision and then selects one of the vertex values of the generated sub-cube as the interpolation result. This hardware implementation of pruned radial interpolation requires only a single multiplexer and a single adder (of course the rounding at the end requires an additional adder but this additional adder is not shown in FIG. 10).
Shown in FIG. 11 is a high level flow diagram of a generalized method of pruned radial interpolation for input color space values 10 having d components with each set of lower order bits 10b having n bits. First, n values are computed 400 using equation 1b, Next, n+1 interpolation data values (which correspond to vertex values in a color space conversion) are selected 401 using the computed n values and higher order bits 10a. Finally, the interpolation result is computed 402 by multiplying and adding the selected n+1 interpolation data values according to equation 3.
A software implementation of the pruned radial interpolation is computationally very efficient. With d input dimensions, D output dimensions and 2 n values between vertices of cubic lattice 1, the number of computations required to generate an interpolation result can be computed as:
# of ALU operations=2×n×(d÷D+1)+D eqn. 6
The number of memory accesses required to generate the interpolation result can be computed as:
# of memory accesses=D×(n+1) eqn. 7
It should be noted that, unlike many other interpolation methods, both the number of ALU operations and the number of memory accesses are linear in D, d, and, n which results in the relative computational efficiency of pruned radial interpolation.
Shown in FIG. 12 is a high level flow diagram of a method implemented in software to perform the pruned radial interpolation. First, a determination 500 is made if any one of the components of the input color space value (a, b, c) 10 corresponds to a location on an outer boundary of the cubic lattice 1. This is the case if any one or more of the components of the input color space value has a value of FF hexadecimal. If this is the case, then, for purposes of generating the index into the cubic lattice 1 to retrieve the necessary vertex values, the components of the input color space value 10 which have a value of FF hexadecimal are assigned 501 a value of 100 hexadecimal.
Assignment of a value of 100 hexadecimal to those input color space values of FF hexadecimal is done to address a special case in the interpolation. To illustrate this special case, consider the representation of the input color space values 10 by eight bits for each component, with each component partitioned into four upper order bits and four lower order bits. With this partitioning, the higher order bits can form the index values 00, 10, 20, 30, . . . F0 hexadecimal for each component. The four lower order bits for each component will be used to interpolate between the output color space values 11 accessed using the index values. The difference between the pair of output color space values 11 accessed using successive index values from 00 hexadecimal to F0 hexadecimal is spanned in 16 equal increments. With each successive increment, the associated value is increased 1/16 of the difference between the accessed pair of output color space values 11, when going from the lower output color space value to the higher output color space value. For example, after 5 increments, the associated value is 5/16 of the difference between the accessed pair of output color space values 11. Using the four lower order bits, the value associated with the corresponding number of increments is added to the output color space value 11 selected using the higher order bits to generate the interpolation result. However a problem arises between index values F0 and FF (index value 100 does not exist in the table) for each component of the input color space value 10. Between F0 and FF there are only 15 increments and the output color space value 11 accessed by FF corresponds to an outer boundary of the output color space. However, the interpolation process is designed to operate on 16 increments between the output color space values 11 accessed using the index values. To address this problem, the output color space values 11 corresponding to the index value FF are mapped to a location having and address of 100 hexadecimal. This mapping effectively distributes the difference in the output color space values 11 corresponding to index values F0 and FF hexadecimal over 16 increments instead of 15. Because of this, there will be slight errors resulting from the interpolation between index values F0 and FF. Although not shown in the hardware block diagrams, the handling of this special case in the interpolation is performed in the hardware implementations of the various interpolator embodiments.
After any necessary reassignment of input color space value 10, the indices used to access the values corresponding to the required vertices of the selected cube in cubic lattice 1 are computed 502. Finally, the values for each component of the output color space value (x, y, z) 11 are computed 503. Provided in FIG. 38 of this specification is the code of an implementation in C, for n=4, of the high level method of pruned radial interpolation show in FIG. 12.
It should be recognized that a number of possible processor specific optimizations of the software for performing pruned radial interpolation can be performed. For example, by combining all the components of each output color space values 11 into a single word, the number of memory accesses required to perform the conversion to the output color space value 11 can be reduced. Another possible optimization exploits the ability of the ALU to perform 32 bit operations. By assigning bits 0-7 of an ALU word to handle the computation of the y component of the output color space value and bits 16-23 to handle the computation of the x component of the output color space value, a single sequence of shifts and adds can be used to generate the x and y components in parallel. It is also possible to implement pruned radial interpolation in hardware. The computational efficiencies which existed in the software implementation of pruned radial interpolation are present in the hardware implementation as reduced hardware requirements.
Tetrahedral interpolation partitions the cube accessed by the higher order bits 10a of the color space input value into a number of tetrahedrons used for generation of the sub-cube containing the result of the interpolation. The resulting sub-cube is then partitioned into tetrahedrons. Two of these tetrahedrons are then used to generate yet another sub-cube containing the result of the interpolation. The successive division of generated sub-cubes into tetrahedrons is performed n times, where n is the number of bits used to represent each of the components of the lower order bits 10b of the input color space value 10.
Shown in FIG. 13 is representation of the outer bounds of a CMY or a RGB color space. As can be seen from FIG. 13, the vertices of the cube 600 formed by the outer bounds of these color spaces include values corresponding to the constituent colors of each of the color spaces. A characteristic of the CMY and RGB color spaces is that the diagonal connected between the white 601 and black 602 vertices of the color space corresponds to the luminance axis. Points along the luminance axis have values which correspond to various shades of gray. As previously mentioned, the higher order bits 10a of the input color space value 10 are used to access eight associated values forming a cube located within cube 600. Analogous to the cube 600 representing the CMY or RGB color space, each of the selected cubes can be regarded as a kind of miniature color space, with the values corresponding to each of the eight vertices having colors which are weighted toward the colors of the corresponding vertices of cube 600. For example, the vertex of the selected cube spatially corresponding to the yellow vertex 603 is the vertex having a value closest to the value for the color yellow within in the selected cube. The other seven vertices of the selected cube can be viewed similarly. The diagonal connecting vertex 0 and vertex 7 serves to define a constant chromance line between the colors associated with the vertices of the selected cube.
Certain artifacts can arise from the reproduction of colors in the printing process. These artifacts are visually perceptible as colors which deviate from those specified by the color space value input to the printing process. The artifacts are particularly noticeable for input color space values located near the luminance axis. Input color space values near the luminance axis correspond to shades of gray with small amounts of color. Factors in the color reproduction process which may push the resulting color farther off the luminance axis than intended are easily perceived in a gray field. The artifacts appear as colors in fields which should include only various shades of gray along the luminance axis. The artifacts can arise from, among other things, the characteristics of the process used for printing (such as an electrophotographic or inkjet printing process) or characteristics of the colorants (such as toner or ink) used in the printing process. Variability in the parameters of the printing process result in the reproduction of colors off the luminance axis when the result should have been gray.
Tetrahedral interpolation, in some circumstances, reduces the degree to which these types of artifacts are perceivable. The reduction in print artifacts occurs because the value of one vertex of the sub-cube generated from the tetrahedron is computed using the values associated with vertex number 0 and vertex number 7. As previously mentioned, the diagonal formed between vertex number 0 and vertex number 7 defines a constant chromance line for the selected cube. Computing a vertex of the sub-cube along this mid-point color boundary line produces a weighting in the interpolation which tends to reduce the rate of change in the output color space value as the input color space value 10 moves off the diagonal of the cube selected by the higher order bits 10a. This in turn tends to somewhat compensate for the variability in printing process parameters which produce non-gray output with gray input color space values.
Shown in FIG. 14 is a graphical representation of the generation of a sub-cube 700 from a tetrahedron 701. Each value of a vertex of the tetrahedron 701 used to compute the value of a vertex of the sub-cube 700 is also a value of a vertex of the cube 702 from which the tetrahedron 701 was partitioned. Let P[k] denote the value associated with vertex k of a cube. Let P'[k] denote the value associated with vertex k of a sub-cube included within the cube having vertex k. It can be shown that the value P'[k] is computed as:
P'[k]={P[k & v(i)]+P[k |v(i)]}÷2 eqn. 8
"&" represents the bitwise AND operation
"|" represents the bitwise OR operation
"k" represents the vertex number
v(i)=4×a(i)+2×b(i)+c(i)
i represents the bit position in the lower order bits 10b in the input color space value
The sub-cube generation that can be accomplished using equation 8 provides a new method of computing vertex values for a tetrahedral interpolation. By using equation 8, the indices used to access the values of the vertices used for computing the sub-cube vertex values can be computed. This provides an advantage over interpolation methods that require accessing of a look-up table in order to determine the indices used to access the vertex values. The use of a look-up table requires memory accesses. As a result, using a look-up table to generate the indices requires a significantly greater number of machine cycles than would be required using the processor to compute the indices. Therefore, using equation 8 to compute the indices used to access the vertex values provides a substantial speed advantage in tetrahedral interpolation over previous methods of performing tetrahedral interpolation. Furthermore, implementing equation 8 in hardware for computation of the multiplexer control inputs used to select the vertex values provides a simpler hardware implementation of tetrahedral interpolation.
As was the case for pruned radial interpolation, the value of vertex number 0 of the last sub-cube generated is the result in the tetrahedral interpolation. It was recognized that not all the values of the vertices of all of the sub-cubes generated were required to generate the result of the interpolation. This led to the development of a further improvement in tetrahedral interpolation referred to as pruned tetrahedral interpolation. Shown in FIG. 15 is a diagrammatic representation of pruned tetrahedral interpolation. In FIG. 15, the prime indicator associated with the term representing the value of each vertex indicates the level of sub-cube generation. For example, terms designated as P'[] represent vertex values after the first cube subdivision iteration, terms designated as P"[] represent vertex values after the second cube subdivision iteration. This method of designating vertex values applies for the generation of successive sub-cubes. FIG. 15 represents the pruned tetrahedral interpolation using 4 bits for the lower order bits 10b of the input color space value 10. The terms shown in FIG. 15 can be generated by starting with the end result of the interpolation P""[0], and determining, successively, using equation 8, the values of the vertices of the previous sub-cube required to generate the values of the vertices of the current sub-cube until the values required to generate the current sub-cube are obtained by accessing the values of the vertices in cubic lattice 1 using higher order bits 10a. As was the case for pruned radial interpolation, the divide by 2 operation is not performed until the value of vertex number 0 of the final sub-cube is obtained in order to prevent the accumulation of rounding errors.
Pruned tetrahedral interpolation provides a substantial computational savings over tetrahedral interpolation. With d input dimensions, D output dimensions, and n lower order bits 10b, the number of computations required to perform the pruned tetrahedral interpolation is computed as: ##EQU2##
It should be noted that, for these equations, the computations vary linearly as a function of d and D for the number of ALU operations, exponentially as a function of d for the number of memory accesses, and exponentially as a function of n for the number of memory accesses. As shown in FIG. 15, pruned tetrahedral interpolation is implemented so that 2 n memory references are required. However, it is possible to implement pruned tetrahedral interpolation so that the number of memory references required is a maximum of 2 d , which for d=3, is the number of vertices within a cube. This is done by recognizing that redundancy exists in the 2 n memory accesses. By using some of the accessed vertex values for multiple of the input values required in FIG. 15 fewer memory accesses are required. Comparing equations 9 and 10 with equations 4 and 5 it can be seen that, with all other things equal, pruned tetrahedral interpolation is more computationally costly than radial interpolation.
Shown in FIG. 16 is a high level flow diagram of a generalized method for performing tetrahedral interpolation. For this method, the input color space values 10 are formed of d components. Each of the d components is partitioned into a set of higher order bits 10a and lower order bits 10b. Each of the d sets of lower order bits 10b is formed of n bits. The d sets of lower order bits are each designated as 1b 1 , 1b 2 , 1b 3 , . . . , 1b d . The bit position of each of the lower order bits is designated from the most significant bit to the least significant bit by a value of i ranging, correspondingly from n-1 to 0. First, a value is computed 800 according to v[i]=2 d-1 ×1b 1 [i]+2 d-2 ×1b 2 [i]+2 d-3 ×1b 3 [i]+ . . . +2 d-d ×1b d [i] for i equal to n-1. Next, a set of AND values is computed 800 according to v[i]& k, for the value of k ranging from 2 d -1 to 0, where "&" represents the bitwise AND operation. Then, a set of OR values is computed 802 according to v[i]|k for the value of k ranging from 2 d -1 to 0, where "|" represents the bitwise OR operation. Next, 2 d pairs of the vertex values are selected 803 using the set of AND values and the set of OR values. Each of the pairs are selected using an AND value and an OR value computed for a corresponding value of k. Finally, a set of 2 d sums is computed 804 by summing each of the 2 d pairs of vertex values.
The method shown in FIG. 16 is for a single iteration of tetrahedral interpolation. Performing successive iterations would require computing additional values of v[i], computing additional AND and OR values, selecting values from 2 d sums computed in the previous iteration using the additionally computed AND and OR values, and computing additional sets of 2 d sums. After the final iteration of tetrahedral interpolation, each of the final 2 d sums is divided by 2 n (not shown in FIG. 16), where n is the number of iterations, and one of the resulting values is selected as the result of the interpolation. The division by 2 n is done after the final iteration, instead of dividing by two after each iteration, to prevent round-off error accumulation.
Shown in FIG. 17 is a hardware implementation of a tetrahedral interpolator 900 for conversion of input color space values 10 to a component of output color space values 11. This same hardware could be used repetitively for an additional (D-1) passes to generate the remaining D-1 components of the output color space value 11. Or, there could be an additional (D-1) replications of part of the hardware implementation shown in FIG. 17 to generate each of D components simultaneously. The hardware used for generating multiplexer control inputs could be used for each of the D replications. The tetrahedral interpolator 900 shown in FIG. 17 corresponds to d=3 and n=4 for the input color space value 10. The hardware implementation shown in FIG. 17 implements equation 8 for the generation of the sub-cube vertex values. The tetrahedral interpolator 900 of FIG. 17 is formed from a first, second, third, and fourth stage 901-904. Each of the four stages 901-904 includes 2 3 adders, one of which is labeled as 905. Each of the four stages 901-904 further includes 2×2 3 multiplexers, one of which is labeled as 906, arranged as 2 3 pairs of multiplexers. Finally, each of the four stages 901-904 includes 2 3 bitwise OR blocks, one of which is labeled as 907, and 2 3 bitwise AND blocks, one of which is labeled as 908.
Each of stages 901-904 performs an iteration of interpolation. Some interpolation applications may require that only a single iteration of interpolation be performed. For a single iteration of interpolation n=1. This corresponds to a hardware implementation of tetrahedral interpolator 900 using only first stage 901. An additional stage would be added for each additional iteration of interpolation required for the particular application.
Each of the inputs of the multiplexers in the first stage 901 are connected to the eight vertex values selected using higher order bits 10a. The two outputs of each pair of multiplexers in first stage 901 are connected to the first and second inputs of the corresponding adder. The output of each of the adders of the first stage 901 is the vertex value of the first sub-cube. As previously mentioned, the division by two for each iteration of sub-cube generation is deferred until the last sub-cube is generated. The vertex values of the last sub-cube generated are divided by 2 n , where n is the number of bits in the lower order bits of the input color space value and n corresponds to the number of stages in the tetrahedral interpolator. The inputs of each multiplexer for the second, third, and fourth stages 902-904 are coupled to the outputs of the adders of the previous stage.
The control input of one the multiplexers of each pair of multiplexers is connected to the output of a bitwise OR block. The control input of the other one of each pair of multiplexers is connected to the output of a bitwise AND block. The multiplexers used in the tetrahedral interpolator 900 have the capability to select one of eight, eight bit values using a three bit control input. The bitwise OR blocks and the bitwise AND blocks each perform, respectively, bit by bit OR operations or AND operations on the values input to them. For this d=3 implementation of tetrahedral interpolator 900, each of the inputs to the bitwise OR blocks and bitwise AND is a 3 bit quantity. The output of each of the bitwise OR blocks and bitwise AND blocks to each of the multiplexers is a 3 bit quantity. The adders associated with each pair of multiplexers performs an addition of the selected eight bit values from each of the multiplexers.
As indicated by equation 8, the vertex number corresponding to the vertex value generated is connected to one of the inputs for each corresponding bitwise OR block and bitwise AND block. Because these values are fixed they can be hardwired to the correct values. The other inputs for each corresponding pair of bitwise AND blocks and bitwise OR blocks in a stage are connected to the value of v[i] corresponding to the stage. For the first stage 901, the value is v[3]. For the second stage 902, the value is v[2]. For the third stage 903, the value is v[1]. For the fourth stage 904, the value is v[0].
Interpolation is performed by supplying the vertex values selected using higher order bits 10a to the multiplexer inputs of the first stage 900 and supplying the appropriate v[i] values to the bitwise OR blocks and bitwise AND blocks of each stage. The tetrahedral interpolator 900 computes the vertex values for four iterations of sub-cube generation. The values P""(7) through P""(0) are the values of the vertices of the fourth sub-cube generated. In this embodiment, P""(0) is selected, divided by 16, and used as the result of the interpolation. The division by 16 is implemented by shifting bits and is not represented in FIG. 17.
One of ordinary skill in the art will recognize that one of the other computed values P""(7) through P""(1) may be selected, divided by 16, and used as the result of the interpolation. Using values corresponding to different vertices of the final sub-cube to generate the interpolation result will bias the result of the interpolation differently. This is a consideration in selecting which vertex value of the final sub-cube generated will be divided by 16 to generate the result of the interpolation.
Shown in FIG. 18 is a hardware implementation of a pruned tetrahedral interpolator 1000 for conversion of input color space values 10 to a component of output color space values 11. This same hardware could be used repetitively for an additional (D-1) passes to generate the remaining D-1 components of the output color space value 11. Or, there could be an additional (D-1) replications of part of the hardware implementation shown in FIG. 18 to generate each of D components simultaneously. The hardware used for generating multiplexer control inputs could be used for each of the D replications. The pruned tetrahedral interpolator 1000 shown in FIG. 18 corresponds to d=3 and n=4 for the input color space value 10. The pruned tetrahedral interpolator 1000 implements the diagrammatic representation of pruned tetrahedral interpolation shown in FIG. 15 The implementation of pruned tetrahedral interpolator 1000 requires considerably less hardware than the implementation of tetrahedral interpolator 900.
For d=3, bitwise AND blocks 1001a through 1001k each perform a bit by bit AND operation on three bit input quantities to generate 3 bit output quantities. Likewise, for d=3, bitwise OR blocks 1002a through 1002k each perform a bit by bit OR operation on 3 bit input quantities to generate 3 bit output quantities. Each of the 3 bit outputs of bitwise AND blocks 1001a-10001g and bitwise OR blocks 1002a-1002g is used to control the selection of one of eight, 8 bit quantities in the corresponding of multiplexers 1003a through 1003n. The outputs of each of multiplexers 1003a-1003o are connected to the inputs of adders 1004a-1004h.
An interpolation operation is performed using pruned tetrahedral interpolator 1000 by supplying the vertex values selected using higher order bits 10a to the inputs of multiplexers 1003a-1003o and supplying the computed values of v[i] to the inputs of bitwise OR blocks 1002a-1002k and bitwise AND blocks 1001a-1001k as shown in FIG. 18. In addition, a vertex value selected using higher order bits 10a is supplied to the input of adder 1004h. Using the computed values of v[i], the bitwise AND blocks 1001a-1001k and the bitwise OR blocks 1002a-1002k compute the values input to the control inputs of multiplexers 1003a-1003n. Multiplexer 1003o uses v[3] directly. The values selected by multiplexers 1003a-1003o are those necessary to compute the interpolation result according to the diagrammatic representation of pruned tetrahedral interpolation shown in FIG. 15. The vertex values selected by multiplexers 1003a-1003o are sent to the inputs of adders 1004a-1004h for summation. The output of the last adder in the chain of additions is divided by 16 and used as the result of the interpolation. The division by 16 is accomplished by bit shifting and is not shown in FIG. 18.
The pruned tetrahedral interpolator shown in FIG. 18 is implemented for d=3 and n=4. For some applications, less than four iterations of interpolation may be sufficient. Other applications may require more than four iterations of interpolation. The hardware implementation of pruned tetrahedral interpolation for d=3 and n=1 would use only a single adder and a single multiplexer to generate P'(0), as shown in FIG. 18. The hardware implementations for n=2 and n=3 to generate, respectively, P"(0) and P"'(0) as shown in FIG. 18, require more bitwise AND blocks, bitwise OR blocks, multiplexers, and adders. Shown in FIG. 19 is a high level flow diagram of a generalized method for performing pruned tetrahedral interpolation. For this method, the input color space values 10 are formed of d components. Each of the d components is partitioned into a set of higher order bits 10a and lower order bits 10b. Each of the d sets of lower order bits 10b is formed of n bits. The d sets of lower order bits are each designated as 1b 1 , 1b 2 , 1b 3 , . . . , 1b d . The bit position of each of the lower order bits is designated from the most significant bit to the least significant bit by a value of i ranging, correspondingly from n-1 to 0. First, 2 n -2 values are computed 1100 according to the types of bitwise AND and bitswise OR operations shown in FIG. 15 with v[i]=2 d-1 ×1b 1 [i]+2 d-2 ×1b 2 [i]+2 d-3 ×1b 3 [i]+ . . . +2 d-d ×1b d [i] for i ranging from n-1 to 0. Next, the minimum of 2 n and 2 d of interpolation data values are selected 1101 using unique ones of the 2 n -2 values computed in step 1100, a value of v[n-1], and higher order bits 10a. Then, the sum of the interpolation data values selected in step 1101 is computed 1102.
The method shown in FIG. 19 is for n iterations of pruned tetrahedral interpolation. The sum computed in step 1102 is divided by 2 n to generate the result. This division is not shown in FIG. 19.
Shown in FIG. 20 is a high level flow diagram of a method implemented in software to perform pruned tetrahedral interpolation. First, a determination 1200 is made if any one of the components of the input color space value (a, b, c) 10 corresponds to a location on an outer boundary of the cubic lattice 1. This is the case if any one or more of the components of the input color space value has a value of FF hexadecimal. If this is the case, then, for purposes of generating the index into the cubic lattice 1 to retrieve the necessary vertex values, the components of the input color space value 10 which have a value of FF hexadecimal are assigned 1201 a value of 100 hexadecimal.
Next, the offsets from the origin of the cube in cubic lattice 1 accessed using higher order bits 10a and the sub-cubes generated during the pruned tetrahedral interpolation are computed 1202 using the relationships shown in the diagrammatic representation of the pruned tetrahedral interpolation of FIG. 15. Then, the indices used to access the values corresponding to the required vertices of the selected cube in cubic lattice in a look-up table are computed 1203. Finally, the values for each component of the output color space value (x, y, z) 11 are computed 1204. Provided in FIG. 40 of this specification is the code of an implementation in C, for n=4, of the high level method of pruned tetrahedral interpolation shown in FIG. 20.
It is also possible to implement pruned tetrahedral interpolation in hardware. The computational efficiencies which existed in the software implementation of pruned tetrahedral interpolation are present in the hardware implementation as reduced hardware requirements. As previously mentioned, shifts and concatenations are implemented without requiring additional hardware elements. The hardware functional blocks required to perform the pruned tetrahedral interpolation include adders, AND gates, OR gates, and multiplexers. With D dimensions in the output color space, d dimensions in the input color space, and n bits representing each group of lower order bits 10b of the input color space value, the requirements of the hardware implementation of the pruned subdivision interpolation can be computed as:
# of Adders=D×2.sup.n eqn. 11
# of Multiplexers=D×(2.sup.n -1) eqn. 12 ##EQU3##
To generate the gate level design necessary to implement the pruned radial interpolation in hardware, a commonly used hardware description language, such as VHDL, may be used. Included in FIG. 41 is a listing of the VHDL code which can generate a hardware implementation of pruned radial interpolation.
As previously discussed, radial interpolation can result in print artifacts in conversions between the RGB and CMY color spaces for certain input color space values. Because of these print artifacts, a tetrahedral interpolation may yield more desirable results. To reduce complexity, the tetrahedral interpolation can be implemented using pruned tetrahedral interpolation, although this interpolation technique is still more computationally intensive than the radial interpolation.
However, for conversions between other color spaces (such as CieLab, LUV, or YC b C r ) the radial interpolation may be preferable because it yields adequate results and is very computationally efficient. Additionally, it is possible that radial interpolation may actually produce more pleasing results than tetrahedral interpolation in some cases. If the interpolation methods are implemented in software, using alternative methods is easily done by calling different routines. However, implementing different interpolation methods in hardware can require separate logic. Because the separate hardware implementations of the two interpolation techniques are under utilized, this solution is expensive.
A common hardware implementation provides the capability for alternatively performing radial interpolation and pruned tetrahedral interpolation with less hardware than a separate hardware implementation of these interpolation techniques. Shown in FIG. 21 is a diagrammatic representation of a common radial interpolation and pruned tetrahedral interpolation implementation. As indicated in FIG. 21, the interpolation technique performed is determined by the vertex values which are input to the hardware. Usually, the number of bits used to express each v(i) term is fewer than the number of bits used to express each of the P[v(i)] terms. Because of this, it is generally less complex to multiplex the v(i) terms prior to the memory access to retrieve the values associated with the P[v(i)] terms.
It should be noted from FIG. 21 that two of the vertex values used for both the radial interpolation and the pruned tetrahedral interpolation are the same for all values of n. Therefore, a common hardware implementation of radial interpolation and pruned tetrahedral interpolation requires an additional 2 n -2 multiplexers (each having d control bits) to be added to the hardware implementation of the pruned tetrahedral interpolation. Included in FIG. 42 is the VHDL code for a hardware implementation of common radial interpolation and pruned tetrahedral interpolation.
Shown in FIG. 22 is a hardware implementation of a common pruned radial and pruned tetrahedral interpolator 1300. The hardware implementation of common pruned radial and pruned tetrahedral interpolation is similar to that of pruned tetrahedral interpolation. The difference is the addition of 14 multiplexers 1301a-1301n used to select the data to the control inputs of multiplexers 1302a-1302n. A single bit is used to control the selection of the data at the inputs of multiplexers 1301a-1301n. The single bit controls whether the multiplexer control inputs to multiplexers 1302a-1302n are for pruned tetrahedral interpolation or for pruned radial interpolation. The multiplexer control input for multiplexers 1302a-1302n determines which of the interpolation data values are coupled to the adders. With the bit in the first of its two states, the hardware of FIG. 22 performs as a pruned radial interpolator. With the bit in the second of its two states, the hardware of FIG. 22 performs as a pruned tetrahedral interpolator.
The control bit for multiplexers 1301a-1301n is used to select between values of v(i) and values computed using bitwise OR blocks 1303a-1303k and bitwise AND blocks 1304a-1304k. Adders 1305a-1305o sum the outputs of mulitplexers 1302a-1302o. By shifting bits, the resulting sum is divided by 16 (not shown in FIG. 22) to generate the result.
The hardware of FIG. 22 could be used repeatitively for an additional (D-1) passes to generate the remaining D-1 components of the output color space value 11. Or, there could be an additional (D-1) replications of part of the hardware implementation shown in FIG. 22 to generate each of D components simultaneously. The hardware used for generating multiplexer control inputs could be used for each of the D replications. The common pruned radial and pruned tetrahedral interpolator 1300 shown in FIG. 22 corresponds to d=3 and n=4 for the input color space value 10. The common pruned radial and pruned tetrahedral interpolator 1300 implements the diagrammatic representation of common pruned radial and pruned tetrahedral interpolation shown in FIG. 21.
In the interpolation process, the higher order bits 10a of an input color space value 10 form an index used to access interpolation data values. The interpolation is performed using the lower order bits 10b of the input color space value. As previously mentioned, the accessed values correspond to the vertices of a cube in a cubic lattice 1. Depending upon the characteristics of the output color space, the values associated with the vertices of the accessed cube may vary at rates dependent upon the dimension of cubic lattice 1 or dependent upon the region of the cubic lattice 1 in which the selected cube is located. Because of this possibility, improved interpolation results may be produced by varying the interpolation resolution between values of the vertices throughout cubic lattice 1 corresponding to the varying rates of change between vertex values. Adjusting the interpolation resolution based upon the location of the selected cube within cubic lattice 1 can be implemented by allowing the partitioning of the input color space value 10 into upper order bits 10a and lower order bits 10b to vary. In regions of cubic lattice 1 having high non-linear rates of change in the values of the vertices, the differences between the values of the vertices would be relatively large using a number of bits not adapted to the color space characteristics to represent each component of the upper order bits 10a. To reduce the values between the vertices, a larger number of bits are used to represent the components of the higher order bits 10a. Consequently, in these regions a smaller number of bits are used to represent the lower order bits 10b. For regions of cubic lattice 1 having lower rates of change or more linear rates of change in the values of the vertices, the differences between the values of the vertices using a number of bits not adapted to the color space characteristics to represent each component of the upper order bits 10a would be relatively small or relatively linear. To increase the values between the vertices a smaller number of bits are used to represent the components of the higher order bits 10a.
To implement an interpolation technique which can support a varying interpolation resolution over the output color space represented by cubic lattice 1, the interpolation technique must accommodate the changing number of bits used to represent the components of the lower order bits 10b. To accomplish this, a value, (n, p, q), is defined so that n bits are used to interpolate between lattice points in the "a" dimension, p bits are used to interpolate between lattice points in the b dimension, and q bits are used to interpolate between lattice points in the c dimension. It is possible to constrain the values of each of the n, p, and q so that they are fixed over the entirety of cubic lattice 1 or to permit each of the values of the n, p, and q to vary independently or co-dependently throughout regions of the cubic lattice 1.
Shown in FIG. 23a through FIG. 23e is a graphical representation of a non-symmetric radial interpolation process that uses 4 bits to represent the a 1 component, 3 bits to represent the b 1 component, and 2 bits to represent the c 1 component of the lower order bits 10b of the input color space value. The first iteration of the cube subdivision is the selection of a sub-cube occupying one half of the cube selected by the higher order bits 10a using the bit from a 1 corresponding to the i=3 position. There are no bits present for the b 1 and the c 1 for the i=3 position. The second iteration of cube subdivision is the selection of a sub-cube occupying one fourth of the previous sub-cube using one bit each from a 1 and from b 1 . The third iteration of cube subdivision is the selection of a sub-cube occupying one eighth of the previous sub-cube using one bit each from a 1 , b 1 , and c 1 . The fourth iteration of cube subdivision is also the selection of a sub-cube occupying one eighth of the previous sub-cube using one bit each from a 1 , b 1 , and c 1 . As can be seen from this, the number of bits of the components of the lower order bits 10b available to generate the sub-cube determines the fraction of the cube used to generate the sub-cube occupied by the sub-cube.
Shown in Table 4 and equations 14 through 19 are the relationships necessary to calculate the values of the sub-cube vertices for each iteration of radial sub-cube generation. Equations 14 through 19 generate the values used in the relationships shown in table 4 so that the correct sub-cube vertex values will be generated with or without the corresponding bits of a 1 , b 1 , and c 1 present for that iteration of sub-cube generation. If for a given iteration of sub-cube generation, a bit in any one or more of a 1 , b 1 , or c 1 is not present, equation 19 will generate the number of the vertex of the cube used in generating a vertex value of the sub-cube to compensate for the missing bit(s).
Mask.sub.a =(2.sup.n -1) eqn. 14
Mask.sub.b =(2.sup.p -1) eqn. 15
Mask.sub.c =(2.sup.q -1) eqn. 16
m[i]=(4×Mask.sub.a [i])+(2×Mask.sub.b [i])+Mask.sub.c [i]eqn. 17
v[i]=m[i]& {(4×a[i])+(2×b[i])+c[i]} eqn. 18
f(N,i)=v[i]|(N&˜m[i]) eqn.
TABLE 4______________________________________ P'[7] = {P[7] + P[f(7,i)]} ÷ 2 P'[6] = {P[6] + P[f(6,i)]} ÷ 2 P'[5] = {P[5] + P[f(5,i)]} ÷ 2 P'[4] = {P[4] + P[f(4,i)]} ÷ 2 P'[3] = {P[3] + P[f(3,i)]} ÷ 2 P'[2] = {P[2] + P[f(2,i)]} ÷ 2 P'[1] = {P[1] + P[f(1,i)]} ÷ 2 P'[0] = {P[0] + P[f(0,i)]} ÷ 2______________________________________
Shown in FIG. 24 is a graphical representation of the generation of a sub-cube 1400 from a cube 1401 using non-symmetric radial sub-cube generation. On the particular iteration of the sub-cube generation shown in FIG. 15, the bit corresponding to the iteration for components b 1 and c 1 is not present. Therefore, the relationships in table 4, with f(N,i) calculated for the bits of b 1 and c 1 corresponding to the iteration not present, dictate that the vertex values P'[7], P'[6], P'[5], and P'[4] are calculated as the average of the values of the two vertices vertically aligned with each of P'[7], P'[6], P'[5], and P'[4]. The computation of vertex values for other combinations in which each of a 1 , b 1 , or c 1 are present or not present is handled analogously by equation 19.
Shown in FIG. 25 is a diagrammatic representation of the non-symmetric pruned radial interpolation computation. The number of computations required to perform the non-symmetric pruned radial interpolation is computed as: ##EQU4##
In FIG. 25, 2 n memory references are shown. However, a selected cube has a maximum of 2 d vertex values, where d is the number of dimensions of the input color space value 10. Therefore, some of the 2 n (16 values for n=4) values shown at the inputs to the diagram of FIG. 25 are redundant. It follows that for 2 n greater than 2 d , the number of memory accesses performed can be limited to the number of vertices in the cube for each dimension of the output of color space. Therefore, the number of memory accesses required for D dimensions in the output color space is:
# Memory accesses=D×min(2.sup.d, 2n) eqn. 21
Shown in FIG. 26 is a high level flow diagram of a generalized method for performing non-symmetric pruned radial interpolation. For this method, the input color space values 10 are formed of d components. Each of the d components is partitioned into a set of higher order bits 10a and lower order bits 10b. The d sets of lower order bits are each designated as 1b 1 , 1b 2 , 1b 3 , . . . , 1b d . Each of the d sets of lower order bits 10b is formed from, respectively, of n 1 , n 2 , n 3 , . . . n d bits. The bit position of each of the d sets of lower order bits is designated from the most significant bit to the least significant bit by corresponding values of i 1 , i 2 , i 3 . . . i d each ranging, correspondingly, from n 1 -1 to 0, n 2 -1 to 0, n 3 -1 to 0, . . . n d -1 to 0. First, a set of 2 n -n-1 values is computed 1500 using f (N,i)=v[i]|(N& ˜m[i]), where m[i]=2 d-1 ×Mask 1 [i]+2 d-2 ×Mask 2 [i]+2 d-3 ×Mask 3 [i]+ . . . +2 d-d ×Mask d [i]. For this computation the values of Mask j =2 k -1 are each computed for a value k selected from n 1 , n 2 , n 3 , . . . n d with the value of j corresponding to the value of the subscript of the selected one of n 1 , n 2 , n 3 , . . . n d . The values of j range from 1 to d. The values of v[i] are computed as m[i]& (2 d-1 ×1b 1 [i]+2 d-2 ×1b 2 [i]+2 d-3 ×1b 3 [i]+ . . . +2 d-d ×1b d [i]) for values of i ranging from n-1 to 0, where n equals the greatest of n 1 , n 2 , n 3 , . . . n d . The value of N corresponds to the vertex numbers ranging from 1 to 2 d . Next, a number of interpolation data values, equal to the minimum of 2 n and 2 d are selected 1501 using the unique values in the set of 2 n -n-1 values, values of v[i] for i ranging from n-1 to 0, and the d sets of higher order bits. Finally, the selected interpolation data values are added 1502 to generate a sum. To avoid roundoff error the generated sum is divided by 2 n . This step is not shown in FIG. 26.
Shown in FIG. 27 is a high level flow diagram of method implemented in software to perform non-symmetric radial interpolation. First, the mask values are generated 1600 for each component of the input color space value 10. Next, a determination 1601 is made if any one of the components of the input color space value (a, b, c) 10 corresponds to a location on an outer boundary of the cubic lattice 1. This is the case if any one or more of the components of the input color space value has a value of FF hexadecimal. If this is the case, then, for purposes of generating the indices to retrieve the necessary vertex values, the components of the input color space value 10 which have a value of FF hexadecimal are assigned 1602 a value of 100 hexadecimal. Then, the values of each of the m[i] and v[i] are computed 1603. Next, the indices used to access each of the vertex values used for the interpolation are computed 1604. Finally, each of the components of the output color space value are computed 1605 using the values accessed by the indices computed in step 1604.
Included in FIG. 43 is a listing in C of the code for a software implementation of non-symmetric radial interpolation. For the non-symmetric radial interpolation, the computed indices correspond to offsets from the origin of the cube selected by the higher order bits 10a. Because of the changing resolution used throughout the output color space, the values of the vertices for three cubes (one cube for each dimension of the output color space) selected by the higher order bits 10a is passed into the routine of FIG. 43 each time color space conversion is performed on an input color space value 10. This is different than the code for the pruned radial and pruned tetrahedral interpolation in which the color table is passed as an array into the routine and indices into this table are computed in the routine. It is also possible to implement non-symmetric radial interpolation in hardware. As previously mentioned, shifts and concatenations are implemented without requiring additional hardware elements. The hardware functional blocks required to perform the non-symmetric radial interpolation include adders, AND gates, OR gates, and multiplexers. With D dimensions in the output color space, d dimensions in the input color space, and n bits representing the maximum number of bits used to represent one of the components of the input color space value, the requirements of the hardware implementation of the non-symmetric radial interpolation can be computed as:
# of Adders=D×[(2.sup.n -1)+1] eqn. 22
# of Multiplexers=D×(2.sup.n -1) eqn. 23 ##EQU5##
To generate the gate level design necessary to implement the non-symmetric pruned radial interpolation in hardware, a commonly used hardware description language, such as VHDL, may be used. Included in FIG. 44 is a listing of the VHDL code which can generate a hardware implementation of non-symmetric pruned radial interpolation.
Shown in FIG. 28 is a hardware implementation of a non-symmetric pruned radial interpolator 1700. Control input computation blocks 1701a-1701k compute the values used by the control inputs of multiplexers 1702a-1702o that are coupled to control input computation blocks 1701a-1701k. Each of control input computation blocks 1701a-1701k performs the computations of equations 14-19 on the input to that control input computation block. As shown in FIG. 28, some of the control inputs of multiplexers 1702a-1702o use values of v[i]. Adders 1703a-1703o sum the outputs of multiplexers 1702a-1702o. This sum is divided by 2 n through bit shifting (not shown in FIG. 28) to generate the interpolation result.
The hardware of FIG. 28 could be used repeatitively for an additional (D-1) passes to generate the remaining D-1 components of the output color space value 11. Or, there could be an additional (D-1) replications of part of the hardware implementation shown in FIG. 28 to generate each of D components simultaneously. The hardware used for generating multiplexer control inputs could be used for each of the D replications. The non-symmetric pruned radial interpolator 1700 shown in FIG. 28 corresponds to d=3 and the maximum one of n 1 , n 2 , n 3 , . . . n d equal to 4 for the input color space value 10. The non-symmetric pruned radial interpolator 1700 implements the diagrammatic representation of pruned tetrahedral interpolation shown in FIG. 25.
Shown in FIG. 29 is a high level flow diagram of a generalized method for performing non-symmetric radial interpolation using the equations of table 4. First, a first set of 2 d values are computed 1800 using f (N, i)=v[i]|(N & ˜m[i]). Next, 2 d pairs of interpolation data values are selected 1801 with each pair formed from the interpolation data value selected using one of the first set of 2 d values and the interpolation data value corresponding the vertex designated by the value of N. Finally, 2 d sums are computed 1802 from the selected 2 d pairs of interpolation data values.
The method shown in FIG. 29 is for a single iteration of non-symmetric radial interpolation. It should be recognized that further iterations would be performed by repeating the steps of FIG. 29 with the successive sets of 2 d values computed using f (N,i) for values of v[i] and m[i] corresponding to successively decremented values of i, selecting successive sets of 2 d pairs of values from the previously computed set of 2 d sums, and computing successive sets of 2 d sums from the successive sets of 2 d pairs of values. After performing n iterations, where n equals the greatest of n 1 , n 2 , n 3 , . . . n d , one of the 2 d sums of the last set computed is divided by 2 n to generate the result. The division by 2 that could be performed after each iteration is delayed until after the final iteration to avoid round-off error.
Shown in FIGS. 30a and 30b is a hardware implementation of a non-symmetric radial interpolator 1900 for conversion of input color space values 10 to a component of output color space values 11. This same hardware could be used repeatitively for an additional (D-1) passes to generate the remaining D-1 components of the output color space value 11. Or, there could be an additional (D-1) replications of part of the hardware implementation shown in FIGS. 30a and 30b to generate each of D components simultaneously. The hardware used for generating multiplexer control inputs could be used for each of the D replications. The non-symmetric radial interpolator 1900 shown in FIGS. 30a and 30b corresponds to d=3 and n=4, where n equals the greatest of n 1 , n 2 n 3 , . . . n d , for the input color space value 10. The hardware implementation shown in FIGS. 30a and 30b implements equations 14-19 and the equations of table 4 for the generation of the sub-cube vertex values. The non-symmetric radial interpolator 1900 of FIGS. 30a and 30b is formed from a first, second, third, and fourth stage 1901-1904. Each of the four stages 1901-1904 includes 2 3 adders, one of which is labeled as 1905. Each of the four stages 1901-1904 further includes 2 3 multiplexers, one of which is labeled as 1906. Finally, each of the four stages 1901-1904 includes 2 3 control input computation blocks for performing the computations of equations 14-19 with the indicated inputs. One of these control input computations blocks is labeled as 1907.
Each of stages 1901-1904 performs an iteration of interpolation. Some interpolation applications may require that only a single iteration of interpolation be performed. For a single iteration of interpolation n=1. This corresponds to a hardware implementation of non-symmetric radial interpolator 1900 using only first stage 1901. An additional stage would be added for each additional iteration of interpolation required for the particular application.
Each of the inputs of the multiplexers in the first stage 1901 are connected to the eight vertex values selected using higher order bits 10a. The outputs of each multiplexer in first stage 1901 are connected to the first input of the corresponding adder. The second input of the adder is connected to the value corresponding to the number of the vertex equal to one of the inputs of the corresponding control input computation blocks. The output of each of the adders of the first stage 1901 is a vertex value of the first sub-cube. As previously mentioned, the division by two for each iteration of sub-cube generation is deferred until the last sub-cube is generated. The vertex values of the last sub-cube generated are divided by 2 n , where n corresponds to the number of stages in the non-symmetric radial interpolator. The inputs of each multiplexer for the second, third, and fourth stages 1902-1904 are coupled to the outputs of the adders of the previous stage.
The control input of each multiplexer is connected to the output of the corresponding control input computation block. The multiplexers used in the non-symmetric radial interpolator 1900 have the capability to select one of eight, eight bit values using a three bit control input. For this d=3, n=4 implementation of non-symmetric radial interpolator 1900, each of the inputs to the control input computation blocks is a 3 bit quantity. The output of each of the control input computation blocks is a 3 bit quantity. The adders associated with each multiplexer performs an addition of the selected eight bit values from each of the multiplexers.
Interpolation is performed by supplying the vertex values selected using higher order bits 10a to the multiplexer inputs of the first stage 1901. The inputs to the control input computation blocks are hardwired. The non-symmetric radial interpolator 1900 computes the vertex values for four iterations of sub-cube generation. The values P""(7) through P""(0) are the values of the vertices of the fourth sub-cube generated. In this embodiment, P""(0) is selected, divided by 16, and used as the result of the interpolation. The division by 16 is implemented by shifting bits and is not represented in FIGS. 30a and 30b.
One of ordinary skill in the art will recognize that one of the other computed values P""(7) through P""(1) may be selected, divided by 16, and used as the result of the interpolation. Using values corresponding to different vertices of the final sub-cube to generate the interpolation result will bias the result of the interpolation differently. This is a consideration in selecting which vertex value of the final sub-cube generated will be divided by 16 to generate the result of the interpolation.
Pruned tetrahedral interpolation can be adapted for implementation in a color space represented by a non-symmetric cubic lattice. As was the case for pruned tetrahedral interpolation, the vertices of the sub-cube generated are computed using the vertices of a tetrahedron partitioned from the cube used to generate the sub-cube. However, for some iterations of sub-cube generation, the corresponding bits of each of the a 1 , b 1 , and c 1 components may not be present. For these cases, the computation of the sub-cube vertices must be modified to compensate for the missing corresponding bits in one or more of the a 1 , b 1 , and c 1 components.
Shown in Table 5 and equations 25 and 26 are the relationships necessary to calculate the values of the sub-cube vertices for non-symmetric pruned tetrahedral sub-cube generation. Equations 25 and 26 along with equations 14 through 18 are used to generate the proper values so that in the relationships listed in table 5, the correct sub-cube vertex values will be generated with or without the bits of a 1 , b 1 , and c 1 corresponding to that iteration of sub-cube generation present. If for a given iteration of sub-cube generation, a bit in any one or more of a 1 , b 1 , or c 1 is not present, equation 25 and equation 26 will generate the number of the vertex of the cube used in generating a vertex value of the sub-cube so that compensation is made for the missing bit(s).
g(N,i)=(v[i]|˜m[i]& N) eqn. 25
h(N,i)=(v[i]|N) eqn.
TABLE 5______________________________________ P'[7] = {P[g(7,i)] + P[h(7,i)]} ÷ 2 P'[6] = {P[g(6,i)] + P[h(6,i)]} ÷ 2 P'[5] = {P[g(5,i)] + P[h(5,i)]} ÷ 2 P'[4] = {P[g(4,i)] + P[h(4,i)]} ÷ 2 P'[3] = {P[g(3,i)] + P[h(3,i)]} ÷ 2 P'[2] = {P[g(2,i)] + P[h(2,i)]} ÷ 2 P'[1] = {P[g(1,i)] + P[h(1,i)]} ÷ 2 P'[0] = {P[g(0,i)] + P[h(0,i)]} ÷ 2______________________________________
Although FIG. 24 provides a graphical representation of the generation of a sub-cube 1400 from a cube 1401 using non-symmetric radial sub-cube generation, FIG. 24 can also provide a graphical representation of non-symmetric pruned tetrahedral sub-cube generation. On the particular iteration of the sub-cube generation shown in FIG. 24, the bit corresponding to the iteration for components b 1 and c 1 is not present. Therefore, the relationships in table 5, with g(N,i) and h(N,i) calculated for the corresponding bits of b 1 and c 1 not present, dictate that the vertex values P'[7], P'[6], P'[5], and P'[4] are calculated as the average of the values of the two vertices vertically aligned with each of P'[7], P'[6], P'[5], and P'[4]. The computation of vertex values for other combinations in which each of a 1 , b 1 , or c 1 are present or not present is handled analogously by equations 25 and 26.
Shown in FIG. 31 is a diagrammatic representation of the non-symmetric pruned tetrahedral interpolation computation. The number of computations required to perform the non-symmetric pruned tetrahedral interpolation is computed as: ##EQU6##
Shown in FIG. 32 is a high level flow diagram of a generalized method for performing non-symmetric pruned tetrahedral interpolation. For this method, the input color space values 10 are formed of d components. Each of the d components is partitioned into a set of higher order bits 10a and lower order bits 10b. The d sets of lower order bits are each designated as 1b 1 , 1b 2 , 1b 3 , . . . , 1b d . Each of the d sets of lower order bits 10b is formed from, respectively, of n 1 , n 2 , n3, . . . n d bits. The bit position of each of the d sets of lower order bits is designated from the most significant bit to the least significant bit by corresponding values of i 1 , i 2 , i 3 . . . i d each ranging, correspondingly, from n 1 -1 to 0, n 2 -1 to 0, n 3 -1 to 0, . . . n d -1 to 0.
First, a set of 2 n -2 values is computed 2000 using g (N, i)=(v[i]|˜m[i]& N) and h(N,i)=(v[i]|N), where m[i]=2 d-1 ×Mask 1 [i]+2 d-2 ×Mask 2 [i]+2 d-3 ×Mask 3 [i]+ . . . +2 d-d ×Mask d [i]. For this computation the values of Mask j =2 k -1 are each computed for a value k selected from n 1 , n 2 , n 3 , . . . n d with the value of j corresponding to the value of the subscript of the selected one of n 1 , n 2 , n 3 , . . . n d . The values of j range from 1 to d. The values of v[i] are computed as m[i]& (2 d-1 ×1b 1 [i]+2 d-2 ×1b 2 [i]+2 d-3 ×1b 3 [i]+ . . . +2 d-d ×1b d [i]) for values of i ranging from n-1 to 0, where n equals the greatest of n 1 , n 2 , n 3 , . . . n d . The value of N corresponds to the vertex numbers ranging from 1 to 2 d . Next, a number of interpolation data values, equal to the minimum of 2 n and 2 d are selected 2001 using the unique values in the set of 2 n -2 values, a value of v[i] for i in the range from n-1 to 0, and the d sets of higher order bits. Finally, the selected interpolation data values are added 2002 to generate a sum. To avoid roundoff error the generated sum is divided by 2 n . This step is not shown in FIG. 32.
Shown in FIG. 33 is a high level flow diagram of a method implemented in software to perform non-symmetric pruned tetrahedral interpolation. First, the mask values are generated 2100 for each component of the input color space value 10. Next, a determination 2101 is made if any one of the components of the input color space value (a, b, c) 10 corresponds to a location on an outer boundary of the cubic lattice 1. This is the case if any one or more of the components of the input color space value has a value of FF hexadecimal. If this is the case, then, for purposes of generating the index into the cubic lattice 1 to retrieve the necessary vertex values, the components of the input color space value 10 which have a value of FF hexadecimal are assigned 2102 a value of 100 hexadecimal. Then, the values of each of the m[i] and v[i] are computed 2103. Next, the indices used to access each of the vertex values used for the interpolation are computed 2104 using g (N,i) and h (N,i). Finally, each of the components of the output color space value are computed 2105 using the values accessed by the indices computed in step 2104.
Included in FIG. 45 is a listing of the code for a software implementation of non-symmetric pruned tetrahedral interpolation in C. For the non-symmetric pruned tetrahedral interpolation, the computed indices correspond to offsets from the origin of the cube selected by the higher order bits 10a. Because of the changing resolution used throughout the output color space, the values of the vertices for three cubes (one cube for each dimension of the output color space) selected by the higher order bits 10a is passed into the routine of FIG. 45 each time color space conversion is performed on an input color space value 10. This is different than the code for the pruned radial and pruned tetrahedral interpolation in which the color table is passed as an array into the routine and indices into this table are computed in the routine.
It is also possible to implement non-symmetric pruned tetrahedral interpolation in hardware. As previously mentioned, shifts and concatenations are implemented without requiring additional hardware elements. The hardware functional blocks required to perform the non-symmetric pruned tetrahedral interpolation include adders, AND gates, OR gates, and multiplexers. With D dimensions in the output color space, d dimensions in the input color space, and n bits representing the maximum number of bits used to represent one of the components of the input color space value, the requirements of the hardware implementation of the non-symmetric pruned tetrahedral interpolation can be computed as:
# of Adders=D×2.sup.n eqn. 29
# of Multiplexers=D×(2.sup.n -1) eqn. 30 ##EQU7##
To generate the gate level design necessary to implement the non-symmetric pruned tetrahedral interpolation in hardware, a commonly used hardware description language, such as VHDL, may be used. Included in FIG. 46 is a listing of the VHDL code which can generate a hardware implementation of non-symmetric pruned tetrahedral interpolation.
Shown in FIG. 34 is a hardware implementation of a non-symmetric pruned tetrahedral interpolator 2200. Control input computation blocks 2201a-2201v compute the values used by the control inputs of multiplexers 2202a-2202n. The control input computation blocks 2201a-2201v apply the functions of equations 25 and 26, as indicated in FIG. 34 to compute the control inputs for multiplexers 2202a-2202n. As shown in FIG. 34, multiplexer 2202o uses a value of v[i] for its control input. Each of mulitplexers 2202a-2202o select from eight interpolation data values selected using higher order bits 10a. Adders 2203a-2203o sum the outputs of multiplexers 2202a-2202o. This sum is divided by 2 n through bit shifting (not shown in FIG. 34) to generate the interpolation result.
The hardware of FIG. 28 could be used repeatitively for an additional (D-1) passes to generate the remaining D-1 components of the output color space value 11. Or, there could be an additional (D-1) replications of part of the hardware implementation shown in FIG. 28 to generate each of D components simultaneously. The hardware used for generating multiplexer control inputs could be used for each of the D replications. The non-symmetric pruned tetrahedral interpolator 2200 shown in FIG. 34 corresponds to d=3 and the maximum one of n 1 , n 2 , n 3 , . . . n d equal to 4 for the input color space value 10. The non-symmetric pruned tetrahedral interpolator 2200 implements the diagrammatic representation of non-symmetric pruned tetrahedral interpolation shown in FIG. 31. Shown in FIG. 35 is a high level flow diagram of a generalized method for performing non-symmetric tetrahedral interpolation. First, a first and a second set of 2 d values are computed 2300 using, respectively g (N,i) and h (N,i). Next, 2 d pairs of interpolation data values are selected 2301 using the first and second set of values. Finally a set of 2 d sums are computed 2302 using the 2 d pairs of interpolation data values.
The method shown in FIG. 35 is for a single iteration of non-symmetric tetrahedral interpolation. It should be recognized that further iterations would be performed by repeating the steps of FIG. 35 with the successive sets of 2 d values computed using g (N,i) and h (N,i) for values of v[i] and m[i] corresponding to successively decremented values of i, selecting successive sets of 2 d pairs of values from the previously computed set of 2 d sums, and computing successive sets of 2 d sums from the successive sets of 2 d pairs of values. After performing n iterations, where n equals the greatest of n 1 , n 2 , n 3 , . . . n d , one of the 2 d sums of the last set computed is divided by 2 n (not shown in FIG. 35) to generate the result. The division by 2 that could be performed after each iteration is delayed until after the final iteration to avoid round-off error.
Shown in FIGS. 36a and 36b is a hardware implementation of a non-symmetric tetrahedral interpolator 2400 for conversion of input color space values 10 to a component of output color space values 11. This same hardware could be used repeatitively for an additional (D-1) passes to generate the remaining D-1 components of the output color space value 11. Or, there could be an additional (D-1) replications of part of the hardware implementation shown in FIGS. 36a and 36b to generate each of D components simultaneously. The hardware used for generating multiplexer control inputs could be used for each of the D replications. The non-symmetric tetrahedral interpolator 2400 shown in FIGS. 36a and 36b corresponds to d=3 and n=4, where n equals the greatest of n 1 , n 2 , n 3 , . . . n d , for the input color space value 10. The hardware implementation shown in FIGS. 36a and 36b implements equations 25 and 26 and the equations of table 5 for the generation of the sub-cube vertex values. The non-symmetric tetrahedral interpolator 2400 of FIGS. 36a and 36b is formed from a first, second, third, and fourth stage 2401-2404. Each of the four stages 2401-2404 includes 2 3 adders, one of which is labeled as 2405. Each of the four stages 1901-1904 further includes 2×2 3 multiplexers, one of which is labeled as 2406. The multiplexers for each stage are arranged into 2 3 pairs. Finally, each of the four stages 2401-2404 includes 2 3 control input computation blocks for computing g (N,i) and 2 3 control input computation blocks for computing h (N,i). One of the control input computation blocks for computing g (N,i) is labeled as 2407 and one of the control input computation blocks for computing h (N,i) is labeled as 2408.
Each of stages 2401-2404 performs an iteration of interpolation. Some interpolation applications may require that only a single iteration of interpolation be performed. For a single iteration of interpolation n=1. This corresponds to a hardware implementation of non-symmetric tetrahedral interpolator 2400 using only first stage 2401. An additional stage would be added for each additional iteration of interpolation required for the particular application.
Each of the inputs of the multiplexers in the first stage 2401 are connected to the eight vertex values selected using higher order bits 10a. The outputs of each pair of multiplexers in stages 2401-1404 are connected to, respectively, the first and second inputs of the corresponding adder. The output of each of the adders of the first stage 1901 is a vertex value of the first sub-cube. As previously mentioned, the division by 2 for each iteration of sub-cube generation is deferred until the last sub-cube is generated. The vertex values of the last sub-cube generated are divided by 2"(not shown in FIGS. 36a and 36b), where n corresponds to the number of stages in the non-symmetric tetrahedral interpolator. The inputs of each multiplexer for the second, third, and fourth stages 2402-2404 are coupled to the outputs of the adders of the previous stage.
The control input of each multiplexer is connected to the output of the corresponding control input computation block. The multiplexers used in the non-symmetric tetrahedral interpolator 2400 have the capability to select one of eight, eight bit values using a three bit control input. For this d=3 implementation of non-symmetric tetrahedral interpolator 2400, each of the inputs to the control input computation blocks is a 3 bit quantity. The output of each of the control input computation blocks is a 3 bit quantity. The adders associated with each multiplexer performs an addition of the selected eight bit values from each of the multiplexers.
Interpolation is performed by supplying the vertex values selected using higher order bits 10a to the multiplexer inputs of the first stage 2401. The inputs to the control input computation blocks are hardwired. The non-symmetric tetrahedral interpolator 2400 computes the vertex values for four iterations of sub-cube generation. The values P""(7) through P""(0) are the values of the vertices of the fourth sub-cube generated. In this embodiment, P""(0) is selected, divided by 16, and used as the result of the interpolation. The division by 16 is implemented by shifting bits and is not represented in FIGS. 36a and 36b.
One of ordinary skill in the art will recognize that one of the other computed values P""(7) through P""(1) may be selected, divided by 16, and used as the result of the interpolation. Using values corresponding to different vertices of the final sub-cube to generate the interpolation result will bias the result of the interpolation differently. This is a consideration in selecting which vertex value of the final sub-cube generated will be divided by 16 to generate the result of the interpolation.
A common hardware implementation of non-symmetric radial interpolation and non-symmetric pruned tetrahedral interpolation is possible. As can be seen from the diagrammatic representations of the non-symmetric radial interpolation and the non-symmetric pruned tetrahedral interpolation in FIG. 25 and FIG. 31, respectively, a common hardware implementation could be accomplished by multiplexing the indices used to access the input vertex values. Included in FIG. 47 is a listing of the VHDL code which can generate a common hardware implementation of non-symmetric radial and non-symmetric pruned tetrahedral interpolation.
Shown in FIGS. 37a and 37b, and 37c is a hardware implementation of a common non-symmetric pruned radial and non-symmetric pruned tetrahedral interpolator 2500. The hardware implementation of common non-symmetric pruned radial and non-symmetric pruned tetrahedral interpolation incorporates the control input computation blocks of the non-symmetric pruned radial 1700 and non-symmetric pruned tetrahedral 2200 interpolators. Multiplexers 2501a-2501n are used to select the data to the control inputs of multiplexers 2502a-2502n. A single bit is used to control the selection of the data at the inputs of multiplexers 2501a-2501n. The single bit controls whether the multiplexer control inputs to multiplexers 2502a-2502n are for non-symmetric pruned tetrahedral interpolation or for non-symmetric pruned radial interpolation. The multiplexer control input for multiplexers 2502a-2502n determines which of the interpolation data values are coupled to the adders. With the bit in the first of its two states, the hardware of FIGS. 37a, 37b and 37c performs as a non-symmetric pruned radial interpolator. With the bit in the second of its two states, the hardware of FIGS. 37a, 37b, and 37c performs as a non-symmetric pruned tetrahedral interpolator. Adders 2503a-2503o sum the outputs of mulitplexers 2502a-2502o. By shifting bits, the resulting sum is divided by 16 (not shown in FIG. 22) to generate the result. Control input computation blocks 2504a-2504k implement equations 14-19 and control input computation blocks 2505a-2505v implement equations 25 and 26.
The hardware of FIGS. 37a, 37b, and 37c could be used repeatitively for an additional (D-1) passes to generate the remaining D-1 components of the output color space value 11. Or, there could be an additional (D-1) replications of part of the hardware implementation shown in FIGS. 37a, 37b, and 37c to generate each of D components simultaneously. The hardware used for generating multiplexer control inputs could be used for each of the D replications. The common non-symmetric pruned radial and non-symmetric pruned tetrahedral interpolator 2500 shown in FIGS. 37a, 37b, and 37c corresponds to d=3 and n=4 for the input color space value 10.
It should be recognized that for each of the disclosed hardware embodiments of interpolators, computations are required to supply the multiplexer control inputs. These computations may be implemented in dedicated hardware or performed using a microprocessor under software control. Using a microprocessor to compute the multiplexer control inputs results in a hardware savings at the expense of increasing the time required to perform the multiplexer control input computations.
Although several embodiments of the inventions have been illustrated, and their forms described, it is readily apparent to those of ordinary skill in the art that various modifications may be made therein without departing from the spirit of the invention or from the scope of the appended claims. | New interpolation techniques allow improved efficiency and speed in performing color space conversions. A radial interpolation technique accomplishes an interpolation by generating successive subcubes. A value of a vertex of the final subcube generated is used as the result of the interpolation. Subcubes are generated by averaging a selected vertex value with the vertex values of each of the remaining vertices. A pruned radial interpolation technique employs a subset of the vertex values of the initially selected cube to generate the result of the interpolation, thereby improving upon the efficiency of the radial interpolation. A tetrahedral interpolation technique accomplishes an interpolation by generating successive subcubes. A value of a vertex of the final subcube generated is used as the result of the interpolation. Subcubes are generated by applying a mathematical relationship which allows computation of subcube vertex values through a series of logical AND, logical OR and averaging operations. A pruned tetrahedral interpolation technique employs a subset of the vertex values of the initially selected cube to generate the result of the interpolation, thereby improving upon the efficiency of the tetrahedral interpolation. A common hardware implementation of pruned radial interpolation and pruned tetrahedral interpolation uses the common hardware structure of the two techniques with multiplexing of the input vertex values to allow performance of either a pruned radial interpolation or a pruned tetrahedral interpolation. Non-symmetric pruned radial and Non-symmetric pruned tetrahedral interpolation permit interpolation using interpolation data values distributed throughout the color space with a resolution that varies according to characteristics of the color space. Multiplexing of the interpolation data values to the non-symmetric pruned radial interpolation hardware and to the non-symmetric pruned tetrahedral interpolation hardware allows for a common hardware implementation. | 6 |
CROSS REFERENCE TO RELATED APPLICATION
This application claims the benefit of U.S. Provisional Application No. 60/624,820 filed Nov. 4, 2004, and is incorporated herein by reference in its entirety.
BACKGROUND OF THE INVENTION
1. Field of Invention
A re-terminable LC connector assembly includes a spring-loaded ferrule holder assembly and a reusable actuation system for termination of the assembly. An LC connector termination and cam tool enables ready assembly, termination and adjustment of the LC connector assembly.
2. Description of Related Art
Fiber optic networks are becoming increasingly commonplace in telecommunications applications due to their increased bandwidth and distance capabilities relative to copper networks. However, compared to copper systems, fiber optic cables and connections are well known for their more critical and difficult termination.
Alignment between abutted glass cores within a fiber optic interface is crucial to the performance of the connection. Additionally, field installation of standard “pot and finish” fiber optic connectors is extremely labor and expertise intensive. In most applications, an installer is required to prepare a fiber end, glue the fiber end in the connector, cleave the excess fiber from the endface of the connector, and polish the endface of the connector to obtain the optimum geometry for optical performance. Endface polishing is difficult and time-consuming step, particularly when using single mode fiber, which achieves best performance when using an automated polishing machine. However, automated polishing machines are often large and expensive, rendering them impractical for field use.
Fiber pigtail connectors were designed to eliminate the need for these lengthy steps. A pigtail connector is factory-prepared with a length of fiber. In the factory, precise polishing machines can be used to achieve a consistent polish. The endfaces can be inspected at the factory to ensure correct endface geometry for optimum performance. In the field, the installer splices a length of fiber to a cable by means of a fusion splicing machine. This eliminates much of the labor time, but requires the installer to purchase a fusion splicing machine and protective sleeve, which are also expensive. This type of connector requires extra storage for protection of the fusion splice.
Fiber stub connectors were designed to eliminate the need for fusion splicing equipment, splice protection, and lengthy termination steps. The fiber stub connector employs a short fiber stub that is spliced to the field fiber within the connector. Stub connectors typically require a crimp to either activate the splice or retain the field fiber, or both. However, the crimping operations, whether occurring at the interface point or at some other point to retain the field fiber, have a tendency to pull the field fiber and stub fiber apart, or otherwise damage the signal-passing function of the interface.
If the connection is found to be poor after the crimping occurs, the connector must be cut off because crimping is most often an irreversible operation. This wastes a stub fiber connector and a length of fiber optic cable and requires a new connector and fiber optical cable end to be terminated. This wastes both parts and labor, and can be an annoyance to a field installer by delaying installation.
A reusable stub connector is desirable. One known reusable or re-terminable fiber stub connector is disclosed in commonly assigned U.S. application Ser. No. 10/647,848 filed Aug. 25, 2003, the subject matter of which is hereby incorporated herein by reference in its entirety.
SUMMARY
Advantageous features are an improved fiber stub connector assembly that is readily and positively terminated in the field using simple termination tools. In exemplary embodiments, the fiber stub connector assembly is reversibly terminated to allow repositioning or replacement of fiber optic cable field fibers if termination is not acceptable in performance.
In exemplary embodiments, a simplified fiber termination cam tool readily actuates an internal cam mechanism of the connector assembly through rotation to releasably terminate the fiber connection in the connector. The tool may be a hand-held tool, or used in conjunction with a connector support structure to provide simplified and expeditious field termination of fiber optic cables. In exemplary embodiments, the cam tool can include a throughbore that enables connection of a patchcord to the stub fiber of the connector during or shortly after termination without removal of the termination tool. Accordingly, field testing of the connection can be made at the site of termination. Moreover, because the exemplary connectors incorporate reversible termination connections, improperly terminated connections can be reversed and the field fiber either repositioned and reterminated, or a fresh field fiber can be provided for a new connection.
Other features and advantages will be recognized when read in light of the following disclosure.
BRIEF DESCRIPTION OF THE DRAWINGS
Various exemplary embodiments will be described in detail, with reference to the following figures, wherein:
FIGS. 1 and 2 are perspective views of a fully assembled re-terminable LC-type connector, with dust caps and boots omitted for clarity, according to a preferred embodiment;
FIG. 3 is an exploded view of the LC-type Opti-Cam connector of FIGS. 1-2 ;
FIGS. 4 and 5 show perspective front and rear views, respectively, of an exemplary connector housing;
FIG. 6 is a perspective view of an exemplary stub ferrule assembly;
FIGS. 7A-7B are perspective front and rear views of an exemplary ferrule holder assembly;
FIGS. 8-9 are perspective front and rear views, respectively, of an exemplary cam sleeve;
FIGS. 10-11 are perspective front and rear views, respectively, of an exemplary cam detent mechanism;
FIGS. 12-13 are front and rear perspective views, respectively, of an exemplary backbone;
FIGS. 14-15 are perspective views of an exemplary ferrule holder assembly in a partially assembled and fully assembled state, respectively;
FIG. 16 shows a cross-sectional view of a cam detent system in the rear of the housing before termination;
FIG. 17 shows a cross-sectional view of the cam detent system of FIG. 16 after termination;
FIG. 18 shows a cross-section through the cam detent system and a backbone stop system before termination;
FIG. 19 shows a cross-section through the cam detent system and backbone stop system of FIG. 18 after termination;
FIG. 20 shows a cross-section through a buffer clamping system before termination;
FIG. 21 shows a cross-section through the buffer clamping system of FIG. 20 after termination;
FIG. 22 shows a cross-section through a fiber clamping system before termination;
FIG. 23 shows a cross-section of the fiber clamping system of FIG. 22 after termination;
FIG. 24 shows a cross-section of a ferrule holder assembly and a cam termination tool before termination;
FIG. 25 shows a cross-section of the ferrule holder assembly and cam termination tool after termination;
FIG. 26 shows a cross-section through the longitudinal centerline of the LC connector assembly in an unmated condition before termination;
FIG. 27 shows a cross-section through the longitudinal centerline of the LC connector assembly or FIG. 26 at full spring travel condition before termination;
FIG. 28 is a side view of an exemplary LC Opti-Cam connector termination tool;
FIG. 29 is a perspective view of an exemplary LC cam tool showing a plurality of internal keyways;
FIG. 30 is an end view of the LC cam tool showing the LC cam tool keyways;
FIG. 31 is an end view of the exemplary LC Opti-Cam connector showing a corresponding plurality of keys that mate with the LC cam tool keyways;
FIG. 32 is a perspective partial cutaway view of the LC Opti-Cam connector showing a ferrule holder with the keys;
FIG. 33 is a side view of the LC cam tool installed in the LC Opti-Cam connector;
FIG. 34 is a partial view of the LC Opti-Cam termination tool of FIG. 28 showing a cradle that receives an LC connector and LC cam tool;
FIG. 35 is a partial view of the LC cradle of FIG. 34 with the LC cam tool installed and an LC connector being slid into engagement;
FIG. 36 is a partial view of the LC cradle of FIG. 34 with the LC cam tool installed and the LC connector being in engagement with the tool;
FIG. 37 is a partial view of the LC cradle with a field fiber inserted into the LC connector and the connector being rotated 90 degrees to clamp the field fiber;
FIG. 38 is a partial view of the LC cradle with a field fiber inserted into the LC connector and the connector being rotated in an opposite direction 90 degrees to unclamp the field fiber, allowing removal or repositioning;
FIG. 39 is a partial view of the LC cradle showing the LC cam tool being removed;
FIG. 40 is a perspective view of an alternative LC cam tool incorporated into a patchcord;
FIG. 41 is a perspective view of an alternative LC cam tool built into the LC cradle; and
FIG. 42 is a perspective view of yet alternative LC cam tool having an enlarged handle.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
An exemplary embodiment of a re-terminable LC type fiber optic connector will be illustrated with reference to FIGS. 1-27 . The fully assembled connector assembly 100 is shown in FIGS. 1-2 and an exploded view is shown in FIG. 3 . LC connector assembly 100 includes an LC connector housing 110 , stub ferrule assembly 120 , planks 130 , ferrule holder 140 , cam sleeve 150 , compression spring 160 , cam detent 170 , and backbone 180 that terminate a fiber optic cable 190 . Cable 190 includes a field fiber 192 , buffer 194 , fibers 196 , and outer body 198 .
Additional details of each component of LC connector assembly 100 will be described with reference to FIGS. 4-15 . FIGS. 4-5 illustrate front and rear views of connector housing 110 . A front bore 111 allows access to ferrule holder 140 when using cam termination tool 200 ( FIGS. 28-42 ). The rear bore includes a longitudinal keying groove 116 that mates with keying rib 156 ( FIGS. 8-9 ) of cam sleeve 150 to maintain the cam sleeve orientation relative to connector housing 110 . The rear bore also includes detent notches 114 that lock the connector orientation before and after 90 degree cam rotation travel. This feature keeps the connector orientation either in the cammed position or the un-cammed position. A spring latch 172 ( FIGS. 10-11 ) from cam detent 170 snaps into the detent notches 114 . This feature keeps the connector orientation either in the cam position or the un-cam position.
The angle and radii of the spring latch 172 assist in controlling the amount of force required to rotate the connector housing 110 and disengage the spring latch 172 from the notches 114 . A notch 112 allows the back of housing 110 to flex in, making clearance for the backbone 180 to snap over the latches 113 on housing 110 . A locking rib 182 of backbone 180 ( FIG. 12 ) slides into the notch 112 to eliminate the ability of the housing 110 backend to flex in during loading of the backbone 180 under test. This feature can also make the connector tamper proof by not allowing the backbone 180 to be removed without breaking the parts. Latches 113 snap into pockets 188 on backbone 180 ( FIGS. 12-13 ) and hold the connector assembly 100 together.
Tamper rib 115 slides into the recess groove 184 of backbone 180 ( FIGS. 12-13 ) and eliminates the ability to remove the backbone 180 from housing 110 without breaking the components. Ferrule holder assembly stop 118 is provided on the interior of the bore 111 and keeps the ferrule assembly 140 from removal out of the front of housing 110 .
FIG. 6 illustrates details of the stub ferrule assembly 120 , which includes a stub fiber 122 , a ferrule 124 , and a shoulder spacer 126 . The stub fiber 122 is bonded inside ferrule 124 and cleaved and polished. The spacer 126 is pressed over the backend to create a shoulder that takes up the space in the ferrule holder bore 143 ( FIGS. 7A-7B ) where the planks 132 and 134 ( FIG. 3 ) are assembled inside of the ferrule holder 140 . Shoulder spacer 126 is made to press over the ferrule 124 and inside ferrule holder assembly 140 . Once the stub ferrule assembly 120 is pressed inside the ferrule holder 140 , the components are glued in place.
The fiber retaining planks 130 ( FIG. 3 ) include upper plank 132 and lower plank 134 (see FIGS. 22 and 23 ). Lower plank 134 includes a longitudinal extending and radially outward projecting rib 136 while upper plank 132 includes a mating face with a V-groove for receiving stub fiber 122 and field fiber 192 . Both planks 132 and 134 are assembled inside ferrule holder 140 . The lower clamp plank 134 may be assembled first and can be pushed to the side of the bore so that rib 136 protrudes out of plank rib slit 142 in ferrule holder 140 . Once the clamping plank 134 is sufficiently seated, the V-groove plank 132 can be installed. The stub ferrule assembly 120 may then be pressed and glued into ferrule holder assembly 140 . This traps the planks 130 (both clamping plank 134 and V-groove plank 132 ) inside ferrule holder 140 .
FIGS. 7A and 7B illustrate details of the ferrule holder 140 . Ferrule holder 140 includes a press/ferrule holder bore 143 that receives the stub ferrule assembly 120 by press fit. The stub ferrule assembly is then bonded by a suitable adhesive to ensure high ferrule retention in the finished product. A plurality of keying ribs 149 are provided around the outer periphery of the bore 143 . In an exemplary embodiment shown, four keying ribs 149 are provided, each being 90 degrees apart. However, other keying arrangements can be provided. The keying pattern is designed to mate with an associated cam termination tool 200 (see FIGS. 35-38 ). Ferrule holder 140 is also preferably provided with at least one key flat 145 . The flat helps key this component in place during the assembly process of the planks 130 and stub ferrule assembly 120 .
At least one, and preferably two, buffer clamp arms 146 are provided around the periphery of the ferrule holder. Preferably, the clamp arms are symmetrically provided around the periphery. In the illustrated embodiment, two clamp arms 146 are provided diametrically opposed to each other. One is shown in the top view of FIG. 7A while the other is shown in the bottom view of FIG. 7B . The dual buffer clamp arms 146 clamp onto the buffered fiber 190 after the cam sleeve 150 is rotated 90 degrees via the housing 110 . By using at least dual clamp arms, a substantially uniform clamping pressure can be applied on the buffered fiber clamped by the arms.
The cam detent 170 ( FIGS. 10-11 ) and ferrule holder 140 must retain the same orientation so that the detent system works within the designed degree of rotation, e.g., 90 degrees or any other desirable rotation angle. This can be achieved by provision of a detent key 144 that protrudes radially outward from the ferrule holder assembly 140 as shown in FIG. 7A . In exemplary embodiments, detent key 144 is designed so as to not disengage the cam detent 170 during linear travel motion of the ferrule holder assembly 140 or normal operation of the connector. The lower side of ferrule holder assembly 140 is provided with a plank rib slit 142 that allows the clamping plank rib 136 of lower plank 134 ( FIG. 3 ) to protrude through the casing of the ferrule holder assembly 140 . This also allows the cam sleeve 150 to compress the planks 132 and 134 together during the termination process.
FIGS. 8 and 9 describe details of an exemplary cam sleeve 150 . A longitudinal keying rib 156 is provided on the outer periphery of cam sleeve 150 . Keying rib 156 mates with keying groove 116 provided on connector housing 110 to lock the orientation of the cam sleeve 150 for rotation with connector housing 110 . However, other keying structures can be provided. An assembly notch 152 is preferably provided to help orient the cam sleeve 150 when installing it onto ferrule holder assembly 140 . This can be achieved, for example, by notch 152 forming a viewing window that can be aligned with the clamping plank's rib 136 , which is protruding through plank rib slit 142 of ferrule holder assembly 140 .
An interior periphery of cam sleeve 150 has a predetermined cam profile that, when the cam sleeve 150 is rotated relative to ferrule holder 140 , compresses the clamping plank 134 inside ferrule holder assembly 140 between first and second positions. The first position is preferably an unconstrained and unterminated position where the clamping plank exerts little or no clamping force on the field or stub fibers and the second position is preferably a constrained and terminated position where the clamping plank 134 is compressed to generate a sufficient clamping pressure on the field and stub fibers to retain them between the planks 132 , 134 . The inner bore of cam sleeve 150 is also provided with a buffer cam profile 154 that mates with the dual buffer clamp arms 146 of ferrule holder assembly 140 to generate a clamping pressure that retains a buffered fiber when the assembly is rotated to the terminated position. Preferably, rings 158 are provided that snap over the dual buffer clamp arms 146 on ferrule holder assembly 140 to lock the cam sleeve 150 onto the ferrule holder assembly 140 .
The compression spring 160 ( FIG. 3 ) is trapped between the cam sleeve 150 and the cam detent 170 to forward bias the ferrule holder assembly 140 in the connector housing.
FIGS. 10 and 11 describe details of the cam detent 170 . Cam detent 170 includes a spring latch 172 that snaps into notches 114 of connector housing 110 to control the amount of force required to rotate the cam 90 degrees between terminated and unterminated positions. The angle and height of the latch 172 are preferably optimized to control the amount of force required. A stop post 178 extends longitudinally from one end of cam detent 170 and interacts with an arcuate detent groove 186 ( FIGS. 12-13 ) within backbone 180 to restrict cam rotation to a desired range of motion, such as the illustrated 90 degrees. However, other ranges of motion could be substituted. Key groove 174 is provided to key the orientation of the cam detent 170 with the ferrule holder assembly 140 . This feature ensures that the cam detent 170 rotates in unison with the ferrule holder assembly 140 and independent of the housing 110 , cam sleeve 150 , and backbone 180 components. A notch relief 176 allows latch 172 to deflect and the housing 110 and cam sleeve 150 to rotate freely. A cam detent ferrule holder bore 173 is sized with a diameter that is preferably optimized to allow a maximum amount of angular float in the connector while maintaining the desired keying system with the ferrule holder assembly 140 .
FIGS. 12 and 13 describe details of the backbone 180 . A recess groove 184 reduces the amount of stress on the walls of the backbone 180 when the housing latches 113 are snapped into pockets 188 . Additionally, tamper ribs 115 ( FIGS. 4-5 ) can be provided to slide into this area and prevent the removal of the backbone without breaking one of the components. This provides an optional tamper proof component to the assembly. Detent groove 186 controls the rotation of the housing 110 in relation to the ferrule holder 140 assembly by defining the degree of freedom of the system and providing specific stop positions where stop post 178 is constrained. External threads 183 may be provided on the rear exterior periphery as shown to trap Kevlar from the jacketed fiber optic cable 190 between the backbone 180 and a Kevlar nut assembly (not shown). This generates high cable retention loads and forms a strain relief mechanism for the fiber optic cable. A locking rib 182 is provided on the interior of backbone 180 that slides into notch 112 of housing 110 to prevent the backbone 180 from being removed without breaking one of the components to provide another tamper proof function.
As better shown in FIGS. 14-15 , ferrule holder assembly 140 receives stub ferrule assembly 120 at its front end and receives cam sleeve 150 over its rear end. During assembly, alignment notch 152 is used to align with the longitudinal slit 142 while cam sleeve 150 is positioned over the assembly 140 . FIG. 14 shows the two assemblies in a partially assembled state, while FIG. 15 shows the two assemblies in a fully assembled state.
FIGS. 16-17 show cross-sectional views of cam detent system details near the rear of housing 110 both before ( FIG. 16 ) and after ( FIG. 17 ) termination. Housing 110 has backbone 180 coaxially provided over its exterior while cam detent 170 is coaxially provided on the interior of housing 110 . Inward protrusion 182 of backbone 180 is received within corresponding channel 112 of housing 110 . Ferrule holder 140 is coaxially located on the interior of cam detent 170 with longitudinally extending protrusion 144 mating with corresponding channel 174 of cam detent 170 . As shown, spring-biased protrusion 172 of cam detent 170 is received within corresponding detent notch 114 of housing 110 .
The initial (unterminated) orientation is as shown in FIG. 16 . However, when the backbone 180 is rotated 90 degrees in the direction shown in FIG. 17 , the housing 110 and cam sleeve 150 (not shown) also rotate. Notice, however, that ferrule holder 140 and cam detent 170 do not rotate when backbone 180 is rotated. This is achieved through retention of ferrule holder assembly 140 by cam tool 200 as better illustrated in FIGS. 35-39 .
FIGS. 18-19 show cross-sectional views of cam detent 170 and backbone 180 in which details of a stop system are illustrated both before and after termination. In particular, these Figures show arcuate detent groove 186 of backbone 180 defining an angular rotation range for stop post 178 protruding longitudinally from cam detent 170 . In a preferred embodiment, the chord section of arcuate detent groove 186 forms positive stops that allow a 90 degree rotation of the cam detent 170 relative to backbone 180 .
FIGS. 20-21 illustrate a buffer clamping system provided within LC connector assembly 100 . Connector housing 110 receives cam sleeve 150 therein. Cam sleeve 150 defines a hollow interior portion 154 that is in an oval or otherwise cammed, non-circular shape. Ferrule holder 140 has a substantially cylindrical outer profile, with buffer clamping arms 146 initially extending radially outward to define a substantially circular interior buffer fiber bore 148 for receiving buffer 194 of fiber optic cable 190 . However, upon termination, by rotation of housing 110 relative to ferrule holder 140 , the interior cam profile 154 changes orientation. This profile when rotated urges buffer clamping arms 146 radially inward, causing a decrease in the size of the buffer fiber bore 148 . This results in a compression force that will retain the buffer 194 of fiber optic cable 190 ( FIG. 3 ) fixedly in place.
FIGS. 22-23 illustrate a fiber clamping system used to clamp field fiber 192 of cable 190 between upper plank 132 and lower plank 134 of plank members 130 . Before termination, as shown in FIG. 22 , planks 132 and 134 are initially spaced apart to receive field fiber 192 therebetween. Connector housing 110 includes a longitudinal protruding channel 116 that receives a mating rib 156 of cam sleeve 150 . This locks rotation of the cam sleeve 150 with connector housing 110 . Cam sleeve 150 also includes an internal cam profile 158 that before termination opposes a protruding rib 136 and allows the protruding rib to project through plank rib slit 142 in ferrule holder 140 .
During rotation, housing 110 and cam sleeve 150 rotate around ferrule assembly 140 . During this rotation, however, the internal cam profile 158 of cam sleeve 150 moves away from protruding rib 136 . This provides a camming action that compresses lower plank 134 towards upper plank 132 and creates a positive clamping force on the field fiber 192 and stub fiber 122 provided between the opposed plank halves 132 , 134 as shown in FIG. 23 .
FIGS. 24-25 illustrate a section of the ferrule holder assembly 140 both before and after termination, respectively. Termination is attained by use of a cam termination tool 200 having a plurality of keyways 210 spaced around an inner periphery that mate with and engage a corresponding one of a plurality of keys 149 provided on the outer circumference of ferrule holder assembly 140 . During termination, connector housing 110 is rotated 90 degrees, as shown in FIG. 25 . During this rotation, only housing 110 rotates. Because cam tool 200 is fixed in position, ferrule holder assembly 140 and stub ferrule assembly 120 do not move. Alternatively, housing 110 could be fixed and cam tool 200 rotated to rotate ferrule holder assembly 140 and stub fiber assembly 120 relative to the housing 110 .
FIGS. 26-27 are side cross-sectional views down the longitudinal centerline that show additional detail of the various cam assembly components. FIG. 26 is in an unterminated but assembled state. FIG. 27 shows the assembly at a full spring travel condition before termination. This view shows the stop structure designed in the connector housing 110 that restricts travel of ferrule holder assembly 140 and stub fiber assembly inside housing 110 and eliminates full compression of spring 160 to a solid height.
FIGS. 28-42 show various tools that can be used to terminate the LC connector assembly 100 described in the above embodiments. Exemplary LC cam tools include an Opti-Cam termination tool 300 that receives and assists in termination and optional diagnostics of the connector assemblies 100 and a cam tool 200 that engages with components within the connector assembly, preventing them from rotation when the remainder of the connector housing is rotated between an initial uncammed position and a cammed termination position. Additionally, a patchcord 400 may be connected between termination tool 300 and the LC connector assembly 100 through the cam tool 200 .
Particular details of the termination tool 300 and cam tool 200 are described with reference to FIGS. 29-39 . FIGS. 29-33 show features of the interconnection between cam tool 200 and connector assembly 100 . In particular, a first exemplary embodiment of cam tool 200 includes a main body 220 containing a front bore 250 in which are provided at least one, and preferably a plurality of keying grooves or keyways 210 sized and spaced to mate with corresponding key 149 provided on ferrule holder assembly 140 of connector assembly 100 . Cam tool also preferably includes a rear bore 260 that is in communication with front bore 250 such that a throughbore is provided. Cam tool 200 also preferably includes a groove 230 that extends over at least a portion of the circumference of main body 220 . Groove 230 provides a retention element that helps constrain one or more degrees of freedom of movement of cam tool 200 relative to termination tool 300 . Cam tool 200 also may include a lever 240 formed as a projection extending radially and longitudinally from the cam tool. Cam tool lever 240 can serve several functions, including use as a manual handle and as a further retention structure for constraining movement of the cam tool when mounted in termination tool 300 .
In the illustrated embodiment, four internal keyways 210 are symmetrically provided within bore 250 and four external symmetrical projecting keys 149 are provided on ferrule holder assembly 140 . However, the size, shape and location of the keys and corresponding keyways can be varied to any desirable pattern that can achieve an interlocking function in which the cam tool 200 and desired portions of connector assembly 140 are interlocked and prevented from substantial rotation relative to each other. Moreover, the size and shape of the outer periphery of ferrule holder assembly 140 and size and shape of front bore 250 can be changed, so long as the leading edge portion of ferrule holder assembly 140 is capable of being received within the front bore 250 and interlocking contact is made between keyways 210 and keys 149 . Thus, when the cam tool 200 is properly mated with connector assembly 100 , cam tool 200 is partially received over at least a portion of the ferrule holder assembly 140 of connector assembly 100 .
Details of termination tool 300 will be described with reference to FIGS. 34-39 . Termination tool 300 includes an LC cradle 310 that provides a support surface for receiving and supporting a movable LC connector assembly 100 during termination procedures. LC cradle 310 includes an upwardly projecting rear support 320 and an upwardly projecting front support 330 . Rear support 320 is sized and shaped to receive and partially constrain a rear portion of the housing 110 of LC connector assembly 100 . In the illustrated embodiment, rear support 320 includes two upstanding side walls 322 and a recess 324 shaped to support and receive at least a lowermost portion of the LC connector assembly housing. This constraint preferably allows limited linear movement of connector assembly 100 in the direction of the arrow in FIG. 35 and rotation about the longitudinal axis of the connector assembly 100 , while constraining lateral motion.
Front support 330 also includes upstanding side walls 332 and a recess 334 . In this exemplary embodiment, front support 330 is also provided with a second recess portion 336 sized and shaped to accommodate lever 200 of cam tool 200 while recess 334 is sized and shaped to accommodate the main body 220 of cam tool 200 . As shown in FIG. 34 , cam tool 200 is moved in the direction of the arrow and secured to front support 330 by one or more retention structures. One such retention structure is attained by designing the shape of the recesses 334 and 336 and the flexibility of sidewalls 332 to tightly hold the cam tool within support 330 . The provision of the second recess 336 and projecting lever 240 act to prevent rotation of cam tool 200 relative to front support 330 . The snap fit of the two components may also constrain longitudinal and lateral movement of cam tool 200 . However, longitudinal constraint can be further constrained by provision of a snap fit groove 338 within recess 334 that mates with groove 230 of cam tool 200 .
Termination of the LC connector assembly 100 will be described with reference to FIGS. 35-39 . As shown in FIG. 35 , cam tool 200 is mounted within front support 330 . LC connector assembly 100 is then positioned in rear support 320 and slid longitudinally in the direction of the arrow into engagement with cam tool 200 . That is, until keyways 210 engage with corresponding keys 149 of the ferrule holder assembly. Once engaged, cam tool 200 , being itself locked from rotation by front support 330 , acts to prevent rotation of ferrule holder assembly 140 .
As shown in FIG. 36 , a first end of a patchcord 400 , such as a 1.25 mm VFL patchcord, can be inserted through rear bore 260 of the cam tool 200 into engagement with the stub fiber assembly of connector 100 . The second end of patchcord 400 can then be connected to a corresponding terminal of termination tool 300 ( FIG. 28 ). Termination tool 300 can include appropriate known mechanical, optical and/or electrical devices to detect and/or diagnose operation of the optical fiber connection being terminated.
In the state shown in FIG. 36 , the fiber optic components within connector assembly 100 are in an unterminated state. A fiber optic cable 190 including a field fiber (unshown) may then be inserted through the backbone of connector assembly 100 as shown in FIG. 37 until the field fiber is extended between the planks and into substantial abutment against the stub fiber. Then, LC cradle 310 may be pushed backwards to create a bow in the field fiber. At this time, the connector housing 110 of connector assembly 100 is rotated a predetermined amount, e.g., 90 degrees in this illustrated embodiment. This rotates components within connector assembly 100 to cause a camming action that clamps the stub fiber and field fiber within planks 130 . While still in the termination tool 300 , the just terminated connection can be tested using patchcord 400 . If the termination is successful, the termination connector assembly 100 can be removed from the termination tool 300 by upward lifting. Terminated connector 100 can then also be removed from cam tool 200 to form a field terminated optical fiber.
In the event of a poor termination, the housing 110 can be rotated in an opposite direction as shown in FIG. 38 . This disengages the clamping action of the planks and various detents and reverses the termination of the field and stub fibers. The field fiber can then be removed from, or repositioned in, the connector assembly at which time a subsequent termination procedure can be initiated to establish a proper termination. Thus, the connector assembly is reterminable and includes reversible termination structure that can be terminated and unterminated while situated within termination tool 300 . Moreover, by integration of the termination tool with patchcord 400 and associated testing equipment, field testing of the connection can be achieved at the time of termination, greatly improving field termination efficiency.
Although cam tool 200 is designed for use with termination device 300 , cam tool 200 can be removed from termination tool 300 and used independently ( FIG. 39 ). This can be achieved by pulling tool 200 upward in the direction of the arrow out of the snap-fit connection. This may be desired to uncam the connector in case of a poor termination.
There are various other configurations of cam tool 200 that are possible. A first alternative cam tool 200 ′ is shown in FIG. 40 . In this embodiment, cam tool 200 ′ is integrated into a test patchcord 400 ′, such as a 1.25 mm VFL patchcord. As in the prior embodiment, cam tool 200 ′ includes appropriate keyways 210 ′. A second alternative is shown in FIG. 41 , in which a cam tool 200 ″ is built into the LC cradle 310 and forms the front support of termination tool 300 . As in the first embodiment, cam tool 200 ″ can include a throughbore that allows connection of a patchcord 400 ″ through the cam tool into engagement with connector assembly 100 . A third alternative cam tool 200 ′″ is shown in FIG. 42 . In this alternative, the cam tool is a separate tool used to manually actuate the Opti-cam mechanism within connector assembly 100 without the use of termination tool 300 . In this embodiment, an installer would load the field fiber through the back of the connector assembly 100 as in prior embodiments. The cam tool 200 ′″ would then be moved into engagement with the connector assembly and either the cam tool 200 ′″ or the housing 110 rotated relative to the other to activate the cam and terminate the fiber. This cam tool 200 ′″ could also be used to uncam or release the termination of a fully terminated connector so as to reverse the termination, allowing either a repositioning of the field fiber to improve operation, or substitution of a new field fiber to form a terminated connection. Thus, the disclosed connector system is completely reterminable.
The exemplary embodiments set forth above are intended to be illustrative, not limiting. Various changes may be made without departing from the spirit and scope of the invention. Therefore, the systems and methods according to this invention are intended to embrace all known, or later-developed, alternatives, modifications, variations, and/or improvements. | An improved, reversibly terminable fiber stub connector assembly is provided that can be readily and positively terminated in the field using simple termination tools. This allows repositioning or replacement of fiber optic cable field fibers if termination is not acceptable in performance. The tool may be a hand-held tool, or used in conjunction with a connector support structure to provide simplified and expeditious field termination of fiber optic cables. The cam tool can include a throughbore that enables connection of a patchcord to the stub fiber of the connector during or shortly after termination without removal of the termination tool. Accordingly, field testing of the connection can be made at the site of termination. | 6 |
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention relates to a suspension of a vehicle, and more particularly to a suspension of a vehicle that can form a stable camber angle even at the time when the vehicle bumps and rebounds as well as when it rolls.
[0003] 2. Brief Description of the Prior Art
[0004] In general, a camber indicates an angle that forms between a center line of wheels and a vertical line about road surface. The camber prevents the bottom part of front wheels from being stretched by weight and also the wheels from being loosened out while a vehicle is running. Especially, it also plays a role to facilitate an easy manipulation of a steering wheel along with an inclination angle of kingpin.
[0005] However, such camber does not always keep its angle constant while the vehicle is running, but changes its angle according to the running state of the vehicle, mainly depending on types of selected suspensions. The different types of changes will be described in accordance with a few types of suspensions.
[0006] First of all, FIG. 1 illustrates a conventional trailing arm type or a double wishbone type of a suspension that has the similar length of upper and lower arms. As shown in FIG. 1, it is possible to design a camber of wheels that can make the vertical motions with almost no change in the camber angle, close to 0 degree, even when the vehicle bumps and rebounds. However, there will be a change in the camber angle as great as the vehicle rolls as shown in FIG. 2, thereby deteriorating grounding capability of a tire tread to weaken cornering force.
[0007] Next, a conventional swing arm type or a double wishbone type of a suspension which has the different length of upper and lower arms, can be designed to keep changes in the camber of wheels 102 close to 0 when the vehicle rolls as shown in FIG. 4. Therefore, it is possible to sufficiently secure the grounding capability of the wheels tread onto the road surface. On the other hand, when the vehicle bumps and rebounds, there will be a change in the camber to deteriorate a straight running stability of the vehicle.
[0008] As described above, there is a problem in the conventional structures of suspensions in that the conventional suspension can optimally facilitate only either when it bumps and rebounds or when it rolls, so that it has had no alternative but bear its structural problem of deteriorating one of the aforementioned motions of the vehicle because the suspension has been designed for a vehicle in simple consideration of either when the vehicle runs straight or when it turns around.
SUMMARY OF THE INVENTION
[0009] It is an object of the present invention to solve the aforementioned problem and provide a camber control suspension of a vehicle that can make its optimum geometry at a straight running or turning state of the vehicle, thereby not only achieving a stable grounding state of tires when the vehicle is straight running with bump/rebound motions, but also forming sufficient grounding force of tires for strong cornering force when the vehicle is turning with a rolling motion.
[0010] In order to accomplish the aforementioned object of the present invention, there is provided a camber control suspension comprising:
[0011] two roll detecting links respectively connected to the front part of a wheel rotational center at a knuckle of a left wheel and to the rear part of the wheel rotational center at a knuckle of a right wheel and forming a shape of letter L by being bent at a position where the links cross with a vertical line passing through the wheel rotational center;
[0012] a rotary support bracket supporting against vehicle body and guiding rotations of the two roll detecting links;
[0013] a differential gear unit having bevel gears installed at each end of the two roll detecting links for both side gears;
[0014] a worm gear formed at a differential gear case of the differential gear unit;
[0015] a camber control rack formed with a gear meshed to the worm gear and horizontally installed with a vehicle axle to make a horizontal linear motion;
[0016] camber control links connecting both sides of the camber control rack to both wheel knuckles; and
[0017] lower links supporting a lower side of the wheel rotational center of the knuckles against a frame.
BRIEF DESCRIPTION OF THE DRAWINGS
[0018] Objects and aspects of the invention will become apparent from the following description of preferred embodiments with reference to the accompanying drawings in which:
[0019] [0019]FIG. 1 illustrates bump/rebound motions of a general trailing arm type or a double wishbone type of a suspension that has the similar length of upper and lower arms;
[0020] [0020]FIG. 2 illustrates a rolling motion of a general trailing arm type or a double wishbone type of a suspension that has the similar length of upper and lower arms;
[0021] [0021]FIG. 3 illustrates a rolling motion of a general swing arm type or a double wishbone type of a suspension that has different length of upper and lower arms;
[0022] [0022]FIG. 4 illustrates a rolling motion of a general swing arm type or a double wishbone type of a suspension that has the similar length of upper and lower arms;
[0023] [0023]FIG. 5 is a plan view for illustrating the structure of a camber control suspension in accordance with the present invention;
[0024] [0024]FIG. 6 is a front view of FIG. 5;
[0025] [0025]FIG. 7 is an explanatory view for illustrating the operational state of a differential gear unit at the time of bump/rebound of a suspension in accordance with the present invention;
[0026] [0026]FIG. 8 is an explanatory view for illustrating the operational state of a differential gear unit at the time of rolling of a suspension in accordance with the present invention; and
[0027] [0027]FIG. 9 illustrates an operational view of a suspension in accordance with the present invention at the time of rolling.
DETAILED DESCRIPTION OF THE INVENTION
[0028] Hereinafter, a preferred embodiment of the present invention will be described in detail with reference to accompanying drawings.
[0029] [0029]FIGS. 5 and 6 illustrate a camber control suspension in accordance with an embodiment of the present invention, comprising: two roll detecting links 3 L, 3 R respectively connected to the front part of a wheel rotational center at a knuckle 1 L of a left wheel and to the rear part of the wheel rotational center at a knuckle 1 R of the right wheel and forming a shape of letter L by being bent at a position where the links cross with a vertical line passing through the wheel rotational center C; a differential gear unit 7 having bevel gears installed at each end of the two roll detecting links for both side gears 5 L, 5 R; a worm gear 11 formed at a differential gear case 9 of the differential gear unit 7 ; a camber control rack 13 formed with a gear meshed to the worm gear 11 and horizontally installed with a vehicle axle to make a horizontal linear motion; camber control links 15 L, 15 R connecting both sides of the camber control rack 13 to both wheel knuckles 1 L, 1 R; and lower links 17 L, 17 R supporting a lower side of the wheel rotational center C of the knuckles 1 L, 1 R against a frame.
[0030] For reference, the camber control rack 13 and camber control rings 15 L, 15 R shown in FIG. 6 are omitted in FIG. 5. Besides, lateral links 19 and tow links 20 can be installed as shown in FIG. 5.
[0031] The two roll detecting links 3 L, 3 R are connected to both knuckles 1 L, 1 R with ball joint links 21 having ball joints at both ends thereof. The ball joint links 21 are vertically installed to transmit the vertical motions of the wheels including the knuckles 1 L, 1 R to the roll detecting links 3 L, 3 R. The roll detecting links 3 L, 3 R are supported against the vehicle body through rotary supporting brackets 23 for rotation according to the vertical motion of the wheels transmitted through the knuckles 3 L, 3 R and ball joint links 21 .
[0032] The differential gear unit 7 has a very similar structure to the conventional differential gear unit. As shown in FIGS. 7 and 8, the bevel gears installed at both ends of the roll detecting links 3 L, 3 R are regarded as side gears 5 L, 5 R. A pinion gears 25 are meshed with the two side gears 5 L, 5 R and a differential gear case 9 separated from the side gears 5 L, 5 R to support a rotational axle of the pinion gear 25 and rotatably installed at the external side of side gears 5 L, 5 R. There is only one difference from the conventional differential gear in that there is no ring gear assembled in the differential gear case 9 to get rotational force from a propeller shaft.
[0033] Besides, the worm gear 11 is installed at the differential gear case 9 , and the camber control rack 13 is meshed thereto, so that the camber control rack 13 can be linearly moved to the direction in parallel to the vehicle axle by rotation of the worm gear 11 . At this time, the worm gear 11 is set for the camber control rack 13 to be linearly moved to the wheel to be rebounded. The camber control links 15 L, 15 R are connected to transmit the linear motion of the camber control rack 13 to the upper side of the wheel rotational center C of the both wheel knuckles 1 L, 1 R. The low links 17 L, 17 R are constructed to support the lower side of the knuckles 1 L, 1 R against the frame of the vehicle body with the similar length of the camber control links 15 L, 15 R.
[0034] Operations of the present invention thus constructed will be described below.
[0035] When both wheels vertically move simultaneously in straight driving or bump/rebound motions of a vehicle, the wheels move similarly to those in the double wishbone type suspension having similar length of arms as shown in FIG. 1 because the length of the camber control links 15 L, 15 R and that of the lower links 17 L, 17 R are similar. At this time, the vertical motion of the knuckles 1 L, 1 R rotates the roll detecting links 3 L, 3 R through the ball joint links 21 , and the roll detecting links 3 L, 3 R are rotated in opposite directions as shown in FIG. 7. Thus, the side gears 5 L, 5 R connected to the roll detecting links 3 L, 3 R are rotated in the opposite directions to further rotate the pinion 25 of the differential gear unit 7 . In other words, the pinion 25 is simply rotated, but the differential gear case 9 providing a rotational axle to the pinion 25 is not rotated.
[0036] Therefore, the camber control rack 13 meshed to the worm gear 11 installed in the differential gear case 9 maintains its fixed state without any movement. The camber control links 15 L, 15 R connected to the camber control rack 13 are operated with the lower links 17 L, 17 R with the special characteristics of the conventional trailing arm type or double wishbone type of a suspension having the similar length of arms. As a result, it is possible that a vehicle can secure a smooth straight running capability with sufficient grounding force of tires with almost no change in the camber when wheels perform bump/rebound motions.
[0037] Next, the vertical motion of the wheels becomes opposite when a vehicle rolls or turns around. The knuckles 1 L, 1 R move to the opposite directions to carry both of the ball joint links 21 to opposite directions, which rotates the two roll detecting links 3 L, 3 R to an identical direction. At this time, two side gears 5 L, 5 R are under a unidirectional rotational force of the roll detecting links 3 L, 3 R. As the two side gears 5 L, 5 R do not rotate a pinion 25 , but revolve the pinion 25 at its fixed state on the circumference. As a result, the differential gear case 9 can be rotated.
[0038] If a description about the operations of the present invention will be made with reference to FIG. 9, rotations of the differential gear case 9 makes it possible for the camber control rack 13 to make a linear motion owing to worm gear 11 . The linear motion is performed to a direction of a wheel, to which the camber control rack 13 is rebound. In other words, in the drawing the linear motion of the camber control rack 13 is made to the left wheel. While the camber control link 15 L pushes the upper part of the knuckle 1 L of the left wheel to outside of vehicle body to thereby result in a change into a positive value of a camber, the upper part of the right knuckle 1 R to be bumped is pulled by the camber control link 15 R to thereby result in a change into a negative value of a camber. However, if the rolling motion of the vehicle body is considered, it is possible for a change in the camber against the road surface to be kept close to 0.
[0039] If the vehicle is turning to the reverse direction or rolling, the camber control rack 13 and two camber control links 15 L, 15 R are moved in the opposite directions and a change in the camber against road surface is kept close to 0, thereby making it possible to continuously secure good grounding force.
[0040] As described above, not only when a vehicle runs straight or turns around, but also when a vehicle rolls or bumps/rebounds, the camber control rack and camber control links can adjust a camber of wheels by stopping or moving according to vertical motion of both wheels to thereby keep the best grounding state of tires against the road surface, thereby making it possible to secure the good capability of grounding tires for safe drive at any running state of a vehicle.
[0041] In addition, the present invention has a similar structure to a double wishbone or multi-link type suspension, so that it is advantageous in securing other functions of the conventional double wishbone or multi-link type suspension in addition to the camber controlling function described above. | The invention relates to a camber control suspension of a vehicle that can form a stable camber angle even at the time when the vehicle rolls as well as when it bumps and rebounds, including a camber control rack and camber control links with a function of controlling camber of wheels by stopping or moving according to the vertical motion of both wheels, thereby achieving the most stable grounding state of tires at all times to sufficiently enhance the grounding force of tires at any running state of the vehicle. | 1 |
This application is a continuation-in-part of Ser. No. 08/579,245 filed Dec. 27, 1995.
BACKGROUND OF THE INVENTION
This invention relates in general to covers for large open topped compartments and, more specifically to a system for installing a cover over a container where the contents extend above the container.
Open topped compartments, such as truck trailers, dump trucks, storage bins and the like used for hauling or storing particulate material such as grain, ash, lime or the like are subject to having the material fall or blow out onto the roadway. Exposure to rain, excessive sunlight, etc., is often damaging to materials being hauled or stored. With materials such as gravel, aggregate or similar materials, having portions of a load fall onto a roadway is undesirable both from the point of view of littering and the danger of the material striking a following vehicle, possibly breaking a windshield or causing an accident. Where heated materials, such as asphalt, are being stored or carried, retention of heat within the container is very desirable.
Many localities now have laws requiring that all open topped vehicle compartments be covered when containing loose or lightweight material. Often, the loads are simply covered with a tarpaulin that is tied to the edges of the open top at intervals around the opening. While sometimes effective, such tarpaulins are difficult for one person to put into place, especially in windy conditions. Often, it is necessary for the operator to climb on the vehicle or bin sides or across the load to secure the tarpaulin, at considerable personal danger. Installation is time consuming and must be carefully done to prevent an edge of the cover from loosening, allowing spillage of part of the load.
Attempts have been made to provide more convenient covers that are rolled or folded at one end of the compartment and can be unrolled or unfolded to cover the load. These arrangements are generally difficult to deploy and do not adequately secure the sides of the cover to the container sides.
Where a container is filled or overfilled with a granular material, such as dirt or gravel, to the point where the material extends above the container walls, moving a cover over the container surface, typically along and generally parallel with the container upper wall edges, is difficult. The cover edge moving along the container edges tends to dig into the material. Forcing the cover edge through the material is difficult, often impossible for a single operator. In addition, some of the material may be spilled or end up on top of the cover, defeating the purpose of the cover, since spilled or loose material on the cover will fall to the roadway, endangering other vehicles and violating laws and regulations governing covered loads.
Thus, there is a continuing need for improvements in deployable covers for open topped compartments and systems for installing them that will fully and uniformly restrain material loaded in the compartment along both the ends and sides of the compartment, can be easily moved into and out of the covering position by one person standing on the ground, will fully cover material that extends above the compartment sides and will avoid forcing heaped material over the compartment side or onto the cover upper surface from which it can fall to the roadway.
SUMMARY OF THE INVENTION
The above-noted problems, and others, are overcome in accordance with this invention by a cover system for generally rectangular open topped compartments which basically comprises a flexible cover sheet sized to cover at least the top of an open top, mechanisms for moving the cover sheet from a rolled up, stored position with the top open and uncovered to a deployed position covering the open top and a means for causing the leading edge of the cover to move up and over any material heaped above the top edges of the container. The cover sheet has first and second ends and opposed sides. A tubular means at a first end of the open top is secured to the first end of said cover sheet and is adapted to having the cover sheet wrapped therearound.
A transverse rod is secured to the second end of said cover sheet adjacent to the opposed sides of the cover sheet. A deployment means, typically a strap or loop, is secured to the center of the rod for unrolling the cover sheet.
A central guide member is provided on the transverse rod adjacent to the deployment means so that as said cover is pulled over heaps of granular material in the compartment that extend upwardly above the plane of the top, the guide will move the transverse rod and cover leading edge up and over the material, carrying said cover sheet edge above the material and preventing the rod and leading sheet edge from digging into the material.
Preferably, the deployment means comprises attachment means such as a strap attached to the center of the transverse rod and a line fastened to the strap and extending over the end of the container toward which the cover is being moved for pulling the cover to the fully deployed position.
A transverse rod end guide means is provided at each end of the rod for guiding the rod along the container edges during movement of the rod and cover between stored and deployed positions.
The guide member as claimed in this application comprises a tubular hub surrounding a central portion of the rod, two flanges extend outwardly of the hub, one extending underneath the cover and one extending beyond the second end of the cover. A strap is secured to the hub underneath the second flange. The first flange lies adjacent to the cover and may be secured thereto if desired or may be left free floating. The second flange preferably extends upwardly at a small angle, preferably from about 5 to 30 degrees.
BRIEF DESCRIPTION OF THE DRAWING
Details of the invention, and of preferred embodiments thereof, will be further understood upon reference to the drawing, wherein:
FIG. 1 is a schematic side elevation view of a truck trailer using the cover installation assembly of this invention;
FIG. 2 is a perspective view of a cover leading edge sub-assembly with a wide cylindrical roller guide means;
FIG. 3 is an exploded view of the rod and roller sub-assembly;
FIG. 4 is a detail view showing an alternate pulling means attachment;
FIG. 5 is a perspective view of a cover leading edge sub-assembly with multiple rounded roller guide means;
FIG. 6 is a perspective view of a cover leading edge sub-assembly with elliptical roller guide means;
FIG. 7 is a perspective view of a cover leading edge sub-assembly with airfoil-shaped guide means;
FIG. 8 is a perspective view of a cover leading edge sub-assembly with multiple straight paddle wheel guide means;
FIG. 9 is a perspective view of a cover leading edge sub-assembly with multiple square cross section roller guide means;
FIG. 10 is a perspective view of a cover leading edge sub-assembly with multiple spiked cylindrical roller guide means;
FIG. 11 is a perspective view of a cover leading edge sub-assembly with widely spaced narrow cylindrical roller guide means;
FIG. 12 is a perspective view of a cover leading edge sub-assembly with a sliding panel guide means;
FIG. 13 is a perspective view of a cover leading edge sub-assembly with multiple curved paddle wheel guide means;
FIG. 14 is a section view taken on line 14--14, but with system in the roll-up mode;
FIG. 15 is a section view taken on line 14--14, but with the system in the deployment mode;
FIG. 16 is a perspective view taken from above of another embodiment of a cover leading edge sub-assembly with a sliding panel guide means; and
FIG. 17 is a perspective view taken from below of the embodiment shown in FIG. 17.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
While the cover installation assembly of this invention may be used with any open topped container, including storage bins and the like, a preferred application is covering an open topped cargo compartment of large trucks, such as dump trucks and material transporting truck trailers of the sort schematically shown in FIG. 1.
Trailer 10 includes a generally rectangular container 11 having high sides 12 with an open top and is adapted to be moved by a conventional tractor 14. Container 11 may have an openable rear side panel and a conventional hydraulic lift mechanism (not shown) to lift the front end and cause granular material to slide out the back. Any suitable granular or particulate material may be carried by such a trailer, such as dirt, sand, gravel, grain, etc.
In order to prevent a load of granular material from having particles blown out of container 11 or, where heaped above the sides 12, slide over a side during truck movement it is desirable (and often legally required) that a cover 16 be installed over the open top of container 11 whenever trailer 12 is moved. A particularly effective cover arrangement is detailed in copending U.S. patent application, Ser. No. 08/258,933, filed Jun. 13, 1994. That cover is stored on a roller at one end of a container and is unrolled to deploy the cover entirely over the open container top. As described, side flaps may be included, to be deployed with the cover. That cover arrangement is very effective, in particular where the container is filled to a level not above the upper edges of the sides 12.
However, with that cover system and many others wherein a cover is moved to the deployed position along the edges of the open top problems may occur where the material is heaped above the sides. The leading edge of the cover will likely dig into the heaped material, making completion of deployment difficult. In addition, some of the granular material may end up on top of the cover, from which it might blow or slide onto the roadway during truck movement.
As seen in FIG. 1, a leading edge guide means, such as an assembly rollers 18, is provided at the leading edge of the deploying cover so that when heaped granular material 20 is encountered, the leading edge can ride up and over the heap. The leading edge guide will also serve to press down on localized heaps of material, helping to spread the material so that all of the material is at or below the top edges of the container sides 12. Thus, one person can deploy the cover by pulling on rope 22, where without leading edge guide rollers 18 or the like the leading edge may dig in to the point where deployment by one person becomes difficult or impossible.
Details of the deployment mechanism and the leading edge guide embodiment comprising rollers 18 are provided in FIGS. 2 and 3.
Cover 16 is formed from a flexible material, typically a fabric or plastic film material. A transverse rod 24 extends through tubular edges 26 in portions of cover 16 adjacent to the sheet sides, typically formed by hemming the edge of cover 16. Cover 16 is cut away between these edge portions to provide room for rollers 18. The deployment means, typically a rope 22, is secured to a loop 28 of flexible material around rod 24 at the center of the sheet edge. Alternatively, rope 22 could be a strap, typically having a width of up to about 2 inches and woven from a high strength material. Such a strap could extend along the end of the cover and be sewn thereto rather than surrounding rod 29, as shown in FIG. 4.
Details of the rod and roller assembly are provided in the exploded view of FIG. 3. A thin cylindrical rod 24 (only small portions of which are shown for clarity in illustrating the other components) extends through the components shown in FIG. 3.
A short tube 30 rotatably fits over rod 24 at the rod center about which tube 28 rides. A roller 18 is mounted on rod 24 on each side of tube 28. Rollers 18 in this preferred embodiment are made up of a central tube 32 and two end caps 34. Tube 32 and caps 34 are formed from any suitable material, such as plastic or aluminum. While one roller 18 on each side of center are preferred, several shorter contiguous tubes could be used, if desired.
An assembly of two washers 36 and spacer 38 is slipped over rod 24 into contact with the outermost end cap 34 at each side of center. The length of spacer 38 is selected to abut the edge 40 of sheet 16 to keep the roller assembly and sheet properly aligned.
At each end of rod 24 a washer 42 and spacer 44 are slipped over the rod to a position abutting the side edge of cover 16. A disk 46 having a small central hole is held to each end of rod 24 by a bolt 48 threaded into a corresponding hole in the end of rod 24. Spacer 44 with washer 42 and disk 46 form an edge guide that moves along the upper side edge of container 12 to cause the cover assembly to stay in alignment with the container top opening during deployment and rewinding.
While rollers 18 may have any suitable dimensions, spacing between centers of about 50 to 70% of the cover width are preferred for optimum deployment efficiency.
FIG. 4 shows an alternative embodiment of the means for pulling cover 16 over container 11. Here the elongated pulling means is a flat strap 52, preferably having a thickness of 0.1 to 0.2 inch and a width of 0.5 to 2 inches, formed from any high strength woven material. Strap 52 extends over tube or bushing 30 (as seen in FIG. 3) and overlaps cover 16. The end of strap 52 over sheet 16 is sewn thereto with high strength thread. If desired, a doubler sheet (not shown) may be sewn to cover 16 to enlarge and reinforce the area to which strap 52 is fastened. This embodiment has the advantage of avoiding bowing of rod 24 during pulling.
Several alternative embodiment of the leading edge guide means are illustrated in FIGS. 5-12.
Each of these guide means replaces rollers shown in FIGS. 1-3. In each of these embodiments, cover 16, transverse rod 24, washers 36 and 42 and tubes 30, 38 and 44 are as discussed above, except that the lengths of tubes 30 and 38 are varied to accommodate the different guide configurations.
As seen in FIG. 5, four widely spaced narrow rollers 60, having equal lengths and widths, preferably having a generally spherical cross section in a plane that includes transverse rod 24 are provided. Preferably rollers 60 are spaced approximately equal distances apart, with the outermost rollers spaced apart about 60 to 80% of the width of cover 16. This embodiment is particularly desirable where rough, large particle size material is being carried, such as large gravel and the like. The narrow, spherical rollers roll easily over such material.
FIG. 6 shows an embodiment using two spaced rollers that have generally elliptical axial or lengthwise cross sections and generally circular transverse cross sections. The centers of the rollers are preferably spaced apart about 50 to 70% of the cover width. While rollers 12 may have any suitable dimensions, diameters in the range of about 2 to 6 inches, lengths of about 2 to 5 times the diameter are preferred for optimum deployment efficiency. The sum of the lengths is preferably about 30 to 70% of the width of sheet 16. These rollers move particularly well over medium sized gravel and the like.
FIG. 7 shows an embodiment using generally tapered, airfoil-like, members 64, which slide up and over heaped material. Members 64 are pivotally mounted on transverse rod 24 which passes through the thicker airfoil leading edge parallel to the leading edge. Best results are obtained where members 64 have thicknesses in the range of about 2 to 6 inches and the sum is of the axial lengths of members 64 is about 30 to 70% of the width of sheet 16.
An embodiment using paddle wheel guide members 66 is shown in FIG. 8. While flexible or stiff blades 68 may be used, flexible blades that deflect only sightly when in contact with a heap of material are preferred. While rollers 18 may have any suitable dimensions, paddle wheel diameters in the range of about 2 to 6 inches are preferred.
"Rollers" 70 having a generally square transverse cross section are shown in FIG. 9. Although four sides to roller 70 is preferred, any suitable polyhedral transverse cross section having three or more sides may be used as desired. While rollers 70 may have any suitable dimensions, diameters across faces in the range of about 2 to 6 inches and total axial lengths of from about 30 to 70% of the width of sheet 16 are preferred.
FIG. 10 shows an embodiment in which rollers 72 have a plurality of outwardly extending spikes 74. Any suitable number of spikes may be used. Preferably spikes 74 extend from about 1 to 3 inches above the roller. Ideally, the rollers 72 have the dimensions mentioned for rollers 18, above. This embodiment is particularly preferred for use with very soft heaped material, since the spikes will help keep the rollers turning and prevent the rollers digging into the heap.
For use with very course, hard heaped material, the embodiment shown in FIG. 11 may be preferred. Two narrow, widely spaced, relatively large diameter rollers 76 are provided on rod 24. While rollers 76 may have any suitable dimensions, diameters in the range of about 4 to 10 inches, and a transverse width to axial thickness ratio of at least 2 are preferred.
An embodiment in which a guide means slides up and over heaped material is shown in FIG. 12. Here, a tubular hub 78 fits around rod 24. Two flanges 80 and 82 are secured to hub 78 at an angle to each other of from about 5 to 30 degrees. First flange 80 is fastened to cover 16, such as by adhesive bonding, sewing or the like. Second flange 82 is secured to hub 78 at an acute angle to flange 89 so that flange 82 extends upwardly as the cover is drawn over a heap of material in the container, sliding up and over the heap. A strap 84 is fastened to tube 78 and/or flange 82 for fastening to a pulling means such as a rope. This arrangement is simple, works especially well with soft material in resisting digging in and will also tend to smooth out the heap.
Another preferred embodiment is shown in FIG. 13-15. This embodiment is generally similar to that shown in FIG. 8, except that here the blades s of each paddle wheel 92 are hinged and curved so that the convex side of each blade 90 contacts the surface of the heaped material as strap 28 is pulled to cover the load. A flexible material which will bend slightly in contact with the heap is preferred for best tracking.
An outer tube 93 is rotatably positioned around an inner tube 94. At least one, and preferably three as shown, blades 90 have edges 96 with a generally circular cross section, each fitted in a channel 98 configured so as to act as a hinge, permitting movement of the blade between the positions shown in the section views of FIG. 14 (roll-up mode) and that shown in FIG. 15 (deployment mode).
As seen in section views in FIG. 14, when the paddle wheel assemblies 92 are pulled in the direction indicated by arrow 100, paddle wheel 92 rotates in the direction indicated by arrow 102 to fold blades 90 against tube 93, allowing the assembly to roll alone material 104.
When paddle wheel assemblies 92 are pulled (by pulling on strap 28, FIG. 13) in the direction indicated by arrow 106 in FIG. 15, each paddle wheel rotates in the direction indicated by arrow 108, causing the free edges of each blade 90 to dig into material 104 and open up to a large diameter that permits the assembly to easily climb up and over a heap of material 104 without pushing the material ahead of the paddle wheels.
FIGS. 16 and 17 shown another embodiment in which the second end of cover 16 includes a guide means slides up and over a heap of material. This embodiment is generally similar to that shown in FIG. 12.
Cover 16, rod 24, washer 42, spacer 44 and arm 77 (or a disk 46 as seen in other Figures) are the same as the corresponding components detailed above. Hub 78 has mounted thereon, such as by welding, two flanges 80 and 82. First flange 80 extends under cover 16 and may have any suitable shape, such as the triangular shape shown, rectangular, semi-circular, etc. Second flange 82 extends away from the second end of cover 16 at a small upward angle to flange 80; preferably from about 5° to 30°. Second flange 82 may have any suitable shape, such as the preferred rectangular shape shown, curved, trapezoidal, etc. Flange 80 may be secured to the underside of cover 16, such as by adhesive bonding, or may be left free floating.
Strap 84 is attached to the approximate center of rod 24 and hub 78. Where flange 80 is secured to cover 16, strap 84 can be conveniently fastened to hub 78 by any suitable means such as rivets, adhesive bonding or attachment to a bracket welded to the hub or screws or bolts extending through hub 78 into rod 42, as desired. Where flange 80 is free floating, strap 84 may be advantageously attached directly to rod 24 by bolts, a bracket or the like extending through hub 78 into rod 24 or directly to rod 24 through a cut away opening in hub 78.
While certain preferred materials, dimensions and arrangements have been described in detail in conjunction with the above description of preferred embodiments, those can be varied, where suitable, with similar results. Other applications, variations and ramifications of this invention will occur to those skilled in the art upon reading this disclosure. Those are intended to be included within the scope of this invention as defined in the appended claims. | A cover system for covering open topped containers such as truck trailers carrying particulate material such as dirt, gravel, grain and the like. The cover is a flexible sheet material sized to cover the open top and can extend over the end and down the sides of the container, if desired. A roller is provided at one end of the open top for rolling up the cover to store the cover with the top open. A transverse rod runs through a hem at the opposite end of the cover. Edge guides on the rod maintain the cover in alignment with the container top when the cover is unrolled over the top. At least one freely rotatable roller or slide is provided on the rod near the rod center. A rope, strap or the like is secured to the rod to pull the rod and cover over the open top. The roller or slide allows the leading end of the deploying cover to ride up and over any heaped granular material in the container to avoid the edge digging into the material, which could prevent further deployment of the cover and could result in spillage of material forced onto the top of the cover. | 1 |
BACKGROUND OF THE INVENTION
The invention relates to a recording medium discharge mechanism for use in printers.
A conventional recording sheet discharge mechanism for printers will be described with reference to FIGS. 5 and 6(a)-6(c). FIG. 5 is a sectional view showing a recording sheet discharge mechanism. A recording sheet S, which has already been printed by a recording head 82, is interposed under pressure between a sheet discharge roller 69 and a sheet discharge biasing roller 72 which are disposed at the front end of a sheet discharge tray 14. The recording sheet S is discharged into the sheet discharge tray 14 by rotating the sheet discharge roller 69 in a direction indicated by the arrow in FIG. 5 from a torque transmitted by a drive means (not shown).
FIG. 6(a) shows the profile of the sheet as discharge rollers 69 including a plurality of rectangular teeth disposed on the outer peripheral surface thereof. Further, as shown in FIG. 6(b), the sheet discharge biasing rollers 72 are disposed so as to be slightly staggered relative to the sheet discharge rollers 69 in the axial direction of the rollers and to be slightly superimposed one upon the other in the radial direction. The printed recording sheet S is interposed between the sheet discharge rollers 69 and the sheet discharge bias rollers 72 so as to form a large wave extending in the width-wise direction of the sheet, as illustrated, causing the sheet to be relatively rigid. The sheet discharge rollers 69 are rotated by a drive means (not shown) such that the recording sheet S is forwarded and discharged. When feeding and discharging the recording sheet S into the sheet discharge tray 14, as shown in FIG. 6(c), as its tail end reaches the sheet discharge rollers 69, the toothed portion formed on the peripheral surface of each sheet discharge roller 69 urges the recording sheet S into the sheet discharge tray 14.
However, the conventional device has experienced the following problems. When printing with an ink jet printer, which prints a recording object while spraying ink droplets onto a recording medium, a printed portion on the recording sheet is still wet when the recording sheet is to be discharged. Since the sheet discharge mechanism shown in FIG. 6 causes the printed recording sheet to be clamped between the sheet discharge roller and the sheet discharge biasing roller, the printed object becomes smeared. Further, since the recording sheet is no longer fed after its tail end passes the area at which it is held between the sheet discharge roller 69 and the sheet discharge biasing roller 72, conveyance of a succeeding recording sheet is obstructed by the tail end of the preceding recording sheet which is still disposed near the sheet discharge roller 69, thus leading to jamming of the sheets.
On the other hand, to discharge a recording sheet which is not curled while using the sheet discharge mechanism shown in FIGS. 6(a)-6(c), the toothed portion pushes the tail end of the recording sheet, thereby allowing the recording sheet to be discharged into the sheet discharge tray. However, if the tail end of the recording sheet is noticeably curled prior to printing, and if the ink jet printer is used, the curl of the tail end of the sheet may become more pronounced. As a result, the tail end of the sheet may be curled to such a degree that the tail end does not contact the toothed groove portion of the sheet discharge roller. In this case, the recording sheet will not be completely discharged by the sheet discharge roller into the sheet discharge tray. Accordingly, a succeeding recording sheet may become jammed by the tail end of the preceding sheet still present on the sheet discharge roller.
SUMMARY OF THE INVENTION
The invention has been made in view of the above circumstances. Accordingly, an object of the invention is to provide a recording medium discharge mechanism for a printer which can properly discharge a printed recording medium into a recording sheet discharge tray independently of the states of the recording means and recording medium.
This object has been achieved by a recording medium discharge mechanism, comprising recording image printing means for printing a recording image on a recording medium, a first roller disposed downstream of the recording image printing means and driven by a drive motor while contacting a back surface of the recording medium, the first roller having a vortically toothed peripheral portion, a second roller disposed so as to face the image forming surface of the recording medium in opposition to the first roller and driven by the first roller and a sheet discharge tray disposed below the first and second rollers for accommodating the recording medium. The toothed portion of the first roller includes a plurality of teeth have inner and outer peripheral surfaces made of materials whose frictional coefficient are different from each other. In particular, the inner surface of each teeth has a frictional coefficient which is larger than that of the outer surface. In this manner, the tail end of the recording medium can be urged into the sheet discharge tray due to the high frictional coefficient of the inner surface of the teeth.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a side view showing the general aspect of an ink jet printer having a recording medium discharge mechanism, which is an embodiment of the invention;
FIGS. 2, 3 and 4, are views showing specific portions of the recording medium discharge mechanism shown in FIG. 1, respectively;
FIGS. 5 and 6(a)-6(c) are views illustrating a conventional recording medium discharge mechanism; and
FIGS. 7 and 8 are views showing other embodiments of the invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Embodiments of the invention will be described with reference to the accompanying drawings.
FIG. 1 generally illustrates an ink jet printer having a recording sheet discharging medium according to a first embodiment of the invention. This printer generally includes a sheet feed section 10, a sheet forwarding section 20 disposed in a recording section, and a sheet discharge section 60 for discharging a recording sheet S in the process of drying it.
In the recording sheet section 20, a gate roller 21 is connected to a drive force transmitting mechanism (not shown) on the side upstream of a carriage 80. Additionally, a driven roller 22 is positioned immediately after a platen 46 arranged downstream of the carriage. The driven roller 22 is so arranged as to rotate at the same circumferential speed as that of the gate roller 21 through a recording sheet belt 23 that is installed between the gate roller 21 and the driven roller 22. The recording sheet forward belt 23 is constructed so that a recording sheet biasing roller 32 biases the belt 23 by a frictional force generated between the belt and the roller. The recording sheet S is conveyed by the sheet feed section 10 until it is clamped between the sheet forward belt 23 and the sheet biasing roller 32, and is recorded by a recording head 82 based on input information. The recording head 82 is secured to a carriage that travels along two guide rails 81, 81 which are installed above the printing section so as to intersect orthogonally in the sheet forwarding direction. The recording sheet S is then forwarded to the sheet discharge section 60 by the sheet forwarding belt 23 and the sheet biasing roller 32.
The sheet discharge section 60 includes a heated air-based drying unit 90, a plurality of sheet discharge rollers 69, and a plurality of sheet discharge biasing rollers 72. As shown in FIG. 2, the sheet discharge biasing rollers 72 are arranged to be slightly staggered relative to the sheet discharge rollers 69 in the axial direction of the rollers and to be slightly superimposed in the radial direction. Accordingly, the ink on the recording sheet S, forwarded by the sheet discharge section 60, is dried by the heated air of the drying unit 90 such that the sheet is deformed in a wave-like manner as a result of being clamped between the sheet discharge rollers 69 and the sheet discharge biasing rollers 72. Therefore, the recording sheet S is thus forwarded to a sheet discharge tray 14 in a relatively rigid state.
As shown in FIG. 3, each discharge sheet biasing roller 72 is formed of a thin plate member whose peripheral surface is provided with triangle-like teeth. Accordingly, even if a portion of the sheet, having a large printing density which has not been dried by the heated air-based drying unit 90, comes into contact with the discharge sheet biasing rollers 72, the recording sheet can be forwarded and discharged without smearing the printed characters due to the relatively small contact area of the roller 72 on the sheet.
Further, as shown in FIG. 4, each sheet discharge roller 69 has its peripheral surface provided with vortical teeth. When a sensor (not shown) detects the tail end of the recording sheet S and the tail end is passing between the sheet discharge rollers 69 and the discharge biasing rollers 72, even if the tail end of the sheet S is curled due to printing, the curled tail end of the recording sheet S can still be contacted by the vortical portions of each sheet discharge roller 69. As a result, a downward force is applied to the recording sheet S, ensuring that the recording sheet will fall into the tray without jamming succeeding sheets. Specifically, the recording sheet S is discharged into the sheet discharge tray 14 by rotating the sheet discharge rollers 69 by a drive means at a circumferential speed higher than the speed prior to the detection by the sensor, and by applying an inertial force to the recording sheet S in the sheet discharge direction while biasing its tail end so as to accelerate the sheet into the tray. Each sheet discharge roller 69 is formed in one piece by a plastic such as PA (polyamide (nylon) resin), polyacetal resin, polycarbonate resin, etc.
FIGS. 7 and 8 are diagrams respectively showing other embodiments of the invention which are different from the one shown in FIG. 4. In FIG. 7, a vortically toothed sheet discharge roller 69 is formed of a roller 69a made of an adhesive rubber as the inner surface of each vortical tooth and a film member 69b as the outer surface. The adhesive rubber roller 69a is made of a rubber material having an extremely large friction coefficient, while the film member 69b is made of a material having a friction coefficient substantially equal to that of plastic.
In FIG. 8, a vortically toothed sheet discharge roller 69 is formed of an adhesive rubber member 69c as the inner surface of each vortical tooth and a roller 69d made of a plastic as a roller body. The adhesive rubber member 69c is bonded to the inner surface of a monolithically formed plastic roller 69d. The adhesive rubber member is made of a material having a friction coefficient far larger than that of the plastic roller 69d.
According to the FIG. 7 and 8 embodiment, the outer surface of the sheet discharge roller 69 is made of a plastic 69d or a member 69b made of a material having a friction coefficient as large as that of the plastic, and, when forwarding the recording sheet S, it applies a frictional force large enough to generate an appropriate forwarding force to the recording sheet S.
When the tail end of the recording sheet S passes through the sheet discharge roller 69, the recording surface at the tail end of the recording sheet S comes into contact with the rubber portions of the sheet discharge roller 69 whose friction coefficient is relatively large. As a result, a strong holding force derived from each rubber portion 69a or 69c allows the recording sheet S to be guided thereby even at its tail end, hence ensuring a proper discharge operation.
As described in the foregoing, the recording sheet discharge mechanism according to the invention includes the sheet discharge rollers whose peripheral surfaces, which come into contact with the back surface of the recording medium, are provided with vortical teeth, and the plate-like sheet discharge biasing rollers whose peripheral surfaces are also provided with teeth, both being arranged adjacent to the sheet discharge tray. Further, when the recording sheet is being discharged into the sheet discharge tray, the circumferential speed of the sheet discharge roller is increased over the normal sheet forwarding speed, thereby allowing the recording sheet to be discharged into the sheet discharge tray without smearing the printed portion. Further, even if the recording sheet is curled, the vortically toothed portion over the peripheral surface of each sheet discharge roller serves to discharge the recording sheet while biasing its curled tail end, thereby ensuring that the recording sheet is discharged into the sheet discharge tray without leaving its tail end contacting the sheet discharge roller. This contributes to preventing sequentially discharged sheets from being jammed. | A recording medium discharge mechanism which discharges a recording medium (S) into a discharge tray (14) using a sheet discharge roller (69) and a sheet discharge biasing roller (72) that confronts the sheet discharge roller (66). The sheet discharge roller (69) has a plurality of vortical teeth extending in the direction of rotation of the sheet discharge roller. When the tail end of the recording medium (S) approaches the discharge roller (69), the circumferential speed of the sheet discharge roller (69) is increased so that the recording medium (S) can be accelerated into the sheet discharge tray (14) while biasing the tail end of the recording medium (S). | 1 |
[0001] This application is a continuation-in-part of application Ser. No. 12/621,682 filed Nov. 19, 2009.
BACKGROUND OF INVENTION
[0002] 1. Field of the Invention
[0003] The subject matter disclosed in this application relates to the art of removing impurities and other contaminants, for example organics, from liquids, for example water, using an electrolytic process.
[0004] 2. Description of Related Art
[0005] Electrolytic processes have been in existence for many years. In each case, the prior equipment has been plagued with a continuous buildup of foreign materials on the electrodes which stops the release of metallic ions and causes pitting and damage to the electrodes. As the electrodes are plated with these foreign materials, more voltage is required to maintain the same amount of metal ions being released. The high power eventually causes the unit to stop functioning properly thus requiring the unit to be shut down. Prior attempts to solve the problem include the use of non conductive and even conductive pellets or balls in a fluidized bed to clean the electrodes. Liquid fluidized beds with, for example a four foot per second fluid velocity are inadequate to remove the deposits from the electrodes. Other approaches include reversing the polarity of the electrodes frequently to keep the electrodes clean. Still another approach is to increase the fluid velocity. These approaches have achieved little or no success.
BRIEF SUMMARY OF THE INVENTION
[0006] The present invention prevents the buildup of oxides and other foreign materials on the electrodes of an electrolytic cell by introducing multivalent powder or strips into the contaminated liquid and by assuring the thickness of the multivalent powder or strips is thin enough to be completely consumed prior to any build up occurring. The metal can be either multivalent metal particles like aluminum, iron, zinc, and magnesium for example, or other coagulating metals whose salts aid coagulation. Multivalent ions, or floc, are produced by the current flowing in the electrode grid, which attracts and attaches to the impurities, both organic and inorganic, and other foreign materials in the water. The metal ions required for flocculation can be produced from appropriate metal powders consisting of one or multiple types of metal powders: iron, zinc, magnesium and aluminum, for example, which can be blended with the feed stream prior to the feed stream entering the main electrolytic cell or introduced directly into the cell. In addition to powdered metal particles, thin strips of multivalent metals are also effective as a source of multivalent ions and can be used in much the same manner as powdered metal particles. In another embodiment of the invention, a porous anode plate electrode is formed by compacting powdered metal particles. Using these plate-like anodes in a conventional electrolytic cell with noble electrodes resulted in formation of multivalent ions with virtually no accumulation of oxides on the electrodes and no major change in the voltage or current. Conventional metal and/or non-fouling noble electrodes or a combination of both can be used in accordance with the invention. The electrodes can either both be coated, with a noble coating such as ruthenium, or both uncoated. With respect to the metal strips, they can also be formed of multivalent ion producing metals such as iron, zinc, magnesium and aluminum, for example. They can also be formed of a noble metal. Furthermore they can be either coated with a noble coating or uncoated. This process also destroys pathogens and removes them from the liquid along with the other impurities and contaminants.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWING(S)
[0007] FIG. 1 is a diagram of a system for preparing an aqueous solution of the powdered metal particles according to an embodiment of the disclosure.
[0008] FIG. 2 is a cross sectional view of an electrolytic cell according to an embodiment of the disclosure.
[0009] FIG. 3 is a cross sectional view of a second embodiment of an electrolytic cell according to the disclosure.
[0010] FIG. 4 is a cross sectional view of a third embodiment of an electrolytic cell according to the disclosure.
[0011] FIG. 5 is an enlarged view of the optional secondary cell.
[0012] FIG. 6 is a schematic showing of another embodiment of an electrolytic cell according to the disclosure.
[0013] FIG. 7 is a schematic showing of a further embodiment of an electrolytic cell according to the disclosure.
DETAILED DESCRIPTION OF THE INVENTION
[0014] Turning now to FIG. 1 , this drawing shows a process for the makeup of the metallic powder liquid stream. Metal powder is added to mixing tank 2 from the metal powder concentrate tank 1 through valve 7 . Make up water 6 is added to the mixing tank 2 and the level is controlled by level controller 5 which controls valve 8 . Once the level is correct, the mixing tank valve 9 opens, the recirculation valve 10 opens and the powdered metal outlet valve 11 remains closed. The mixing tank recirculation pump is then started and the mixture flows into an optional secondary cell 3 where the metal powder could be consumed during a timed cycle and the metal ions would then flow through the recirculation valve 10 and back into the mixing tank 2 . This cycle would continue until all the metal powder is consumed and the metal floc would remain in the mixing tank 2 until metered through the powdered metal outlet valve 11 into the primary cell 12 shown in FIG. 2 at a flow rate which is based on the feed rate of the raw feed 14 . If the optional secondary cell 3 is not installed, the flow from the mixing tank recirculation pump 4 would flow through the recirculation valve 10 and back into the mixing tank 2 . The continued circulation helps to keep the powdered metal in solution and also acts as the pump which feeds the metal powder injection stream 17 to the primary cell 12 . Thus while a secondary cell 3 has been shown in FIG. 1 , this is not necessary to carry out the principles according to one embodiment of the invention. Also it is possible to directly introduce the powder particles into the primary cell without prior mixing of any kind.
[0015] FIG. 2 illustrates an embodiment of the primary cell. Fluid to be treated is introduced into cell 12 via an input conduit 14 . Powdered metal particles may be introduced into the input conduit 14 . A plurality of mixing baffles 18 can be provided within the cell for mixing the powdered metal particles with the fluid to be treated. It is noted however that powdered metal input conduit 17 could be directly connected to the primary cell for mixing with the fluid to be treated within the cell itself. A plurality of planar type electrodes 15 are positioned within the cell. The electrodes 15 are alternately connected to the positive and negative portions of a current source as is well known in the art. The electrodes may be obtained from various sources such as Optimum Anode Technologies. An outlet for the treated fluid is provided at 16 . Treated fluid from outlet 16 can be directed to a storage tank where the treated solids and floc can be removed using known techniques. Powdered metal particles up to approximately 0.0625 inches in diameter can be used most effectively.
[0016] FIG. 3 illustrates an alternate embodiment of primary cell 12 . Primary cell 12 has electrodes 15 which are installed transversely to the flow of the raw feed 14 . This type of electrode 15 can be a mesh or expanded metal structure with noble metal coatings such as ruthenium. This type of electrode 15 allows the raw feed 14 and metal powder mixture to flow through the electrodes in lieu of flowing parallel with the electrodes. This arrangement is useful in the removal of some contaminants such as benzene. This arrangement also shows external mixing baffles 18 , which act the same way as the mixing baffles 18 shown in FIG. 2 .
[0017] FIG. 4 illustrates a further embodiment of primary cell 12 . In this embodiment, the electrodes 15 are shown in a longitudinal array. Mixing baffles 18 are made of round tubing or rods with noble metal coatings which can be connected to alternating current or direct current for additional electrode surface area. The placement of the round mixing baffles 18 which can act as additional electrodes can also allow more residence time of the raw feed in the electrolytic field for the destruction of pathogens. This round tubing coated with a noble metal design can also act as a replacement for the plate or mesh type electrodes 15 used in either the primary cell 12 or the secondary cell 3 .
[0018] FIG. 5 shows the optional secondary cell 3 and the flow of powdered metal stream through the cell. The powdered metal stream will originate from the inlet from recirculation pump 20 and flow into the mixing baffles 18 which can be tubing, plate or other types of mixing baffles 18 but can also be round tubing coated with a noble coating such as ruthenium and connected to either alternating current or direct current. This design adds additional electrode surface area to the secondary cell 3 . The electrodes 15 can be longitudinal noble plates, a noble metal mesh or other noble metal coated types of electrode designs. This optional secondary cell 3 would be used to generate metallic ions which are stored in the mixing tank 2 to be directly injected utilizing the metal powder injection stream 17 into the raw feed 14 streams either ahead of the primary cell 12 or directly into the cell 12 .
[0019] FIG. 6 illustrates a further embodiment of the invention wherein in lieu of powdered metal particles, thin strips of multivalent metals or other coagulating metals are used. Electrodes 51 , 52 formed of a noble or consumable metal are connected to the positive and negative terminals of a suitable source of electrical current 59 . Pieces or strips of multivalent metal 60 approximately fifty thousandths of an inch thick or thinner are placed within the cell housing 62 and are subsequently dispersed in the fluid to be treated which enters through inlet 53 . The treated fluid is withdrawn from the cell 61 through outlet 54 . The electrodes 51 and 52 can optionally be coated with suitable coating such as ruthenium. A thin sheet of non conductive cloth can be used to prohibit scratching of the electrodes or to shield the electrodes from contact with the strips or other bodies. In one embodiment the thin metal material is in the form of cylindrical containers similar to those commonly used for beverages. The metal strips may take the form of woven metal cloth, woven metal pads, planar strips, or other sizes and shapes. In this embodiment, electrodes 51 and 52 must either be exposed to contact with the bodies 60 or both be shielded from contact with the bodies. This is because it is necessary from time to time to reverse the polarity of the electrodes. The thin strips or bodies have a thin film of the fluid on them which allows for current to pass but does not create a shorting out of the circuit. Thus if the bodies did not contact both electrodes, reversal of polarity could not be achieved if one electrode was shielded from the bodies. In the event both electrodes are isolated, reverse polarities can be achieved by merely changing the polarity of the electrodes.
[0020] A test apparatus according to the embodiment of FIG. 6 was constructed as follows. The electrolytic cell consisted of a square container approximately eighteen inches square and fourteen inches deep. Two noble electrodes were placed on opposite sides of the container as shown. The power source varied between three to ten volts and the current varied between 15 to 50 amps, D.C. The box was filled with empty aluminum beverage cans to approximately two inches from the top of the electrodes. A flow of approximately one gallon per minute of fluid to be treated was initiated. The thin film of water between each of the beverage cans was sufficient to stop any shorting or arcing between the cans. Conductivity was excellent. The result was that the cans were consumed almost completely without any building of a coating on the electrodes that would normally stop the process. A pair of non-conductive containment screens 63 may be positioned within the housing.
[0021] FIG. 7 illustrates another embodiment of the invention. In this embodiment the electrolytic cell 70 includes an inlet 74 , outlet 75 , and a series of noble or consumable electrodes 72 , which may be coated with a suitable coating. A plurality of specially constructed planar electrodes 71 are positioned between the planar electrodes 72 . Electrodes 72 are connected to the negative terminal of a DC power source 79 and electrodes 71 are connected to the positive terminal of a DC power source 79 . Electrodes 71 are formulated as follows. A ⅜ inch layer of aluminum powder is placed in a three inch chamber mold. A three inch diameter aluminum mesh screen made of 1/16 inch mesh is placed on top of the powder layer. Another ⅜ inch layer of aluminum powder is placed on top of the mesh screen. A flat plate is placed on top of the aluminum powder and a compressive force is applied to the mold to a point where a rigid 3 inch diameter electrode is formed. The resulting electrode is porous and fluid permeable.
[0022] In an actual test, the spacing between the electrodes 71 and 72 was approximately ¼ inch. The applied voltage was approximately 20 volts and the current was approximately 2.5 amps. After about 38 hours of emerging in a fluid stream, there was no accumulation of oxides on the electrodes and there were no major changes in the voltage of current. The electrodes 71 were approximately ¾ consumed with no fouling. The lightly compressed powder was consumed in layers which prevented any oxide coating to form on the anode. Thus there was a continuous release of multivalent ions. In lieu of aluminum powder, other multivalent producing metal power particles as identified above can be used.
[0023] The electrodes 71 of FIG. 7 could also be formed by pressing together several sheets of metal foil, such as aluminum foil.
[0024] Although specific details of an embodiment have been disclosed, it is apparent that other arrangements are possible that would fall within the scope of the claims. For example, various mixtures of different powdered metals can be used and separate mixing hoppers can be used for different powdered metals and injected at the same time or separately. The shape and form of the metal electrodes can be plates, wire mesh, round bars or round tubing, or other shapes, and the electrodes in the primary cell could also be a consumable metal such as iron or a mixture of consumable metal and noble metal electrodes. Furthermore the number of electrodes in the primary cell can be selected based on the flow rate and the residence time required to consume the powdered metal.
[0025] Additionally, the primary cell and the secondary cell can be powered by direct current or alternating current with voltages and amperage being controlled based on the flow rate and the waste stream being treated. The primary cell can be completely sealed allowing vertical installation or it could be installed horizontally without being sealed. Also multiple primary cells could be employed using different powdered metal from separate mixing hoppers.
[0026] In order to prevent any deposits from forming on the electrodes of the primary and secondary cells, the current can be reversed periodically.
[0027] Detailed descriptions of the different embodiments are provided herein. It is to be understood, however that the present invention may be embodied in various forms. For example, the thin metal strips or other configuration of thin metal as discussed in the embodiment of FIG. 6 could be used as a substitute for the powder metal particles used for forming multivalent ions within container 2 shown in FIG. 1 . Therefore, specific details disclosed herein are not to be interpreted as limiting, but rather a basis for the claims and as a representative basis for teaching one skilled in the art to employ the present invention in virtually any appropriately detailed system, structure or manner.
[0028] Although the present invention has been described with respect to specific details, it is not intended that such details should be regarded as limitations on the scope of the invention, except to the extent that they are included in the accompanying claims. | A method and system for purifying liquid is disclosed that includes combining powdered metal particles with the fluid to be treated. The mixture of powdered metal particles or metal and liquid to be treated is then passed through an electrolytic cell. The cell forms multivalent ions which attach to contaminants in the liquid and are subsequently separated out from the liquid using conventional solid/liquid separation techniques. The multivalent ions may also be formed from thin strips of aluminum or formed by pressing layers of powdered metallic particles together and installing in the electrolytic cell between two cathodes, the powdered metal electrode being the anode. | 2 |
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The invention relates to the field of tissue engineering, production of connective tissue linked to natural bones or synthetic bone substitutes (tendons, ligaments, cartilage, etc.) can benefit from the invented procedure. The procedure of the present invention is carried out to produce bioengineered connective tissue substitutes. Connective tissue substitutes (CTS) of the invention may be constructed for replacement of ligaments, and most particularly cruciate ligaments or tendons.
[0003] 2. (b) Description of Prior Art
[0004] Researchers in the surgical arts have been working for many years to develop new techniques and materials for use as grafts to replace or repair damaged or torn tissue structures, particularly bones and connective tissues, such as ligaments and tendons, and to hasten soft tissue repair. It is very common today, for instance, for an orthopedic surgeon to harvest a central portion of patellar tendon of autogenous or allogenous origin for use as a replacement for a torn cruciate ligament. The surgical methods for such approaches are well known. Further it has become common for surgeons to use implantable prostheses formed from plastic, metal and/or ceramic material for reconstruction or replacement of physiological structures. Yet despite their wide use, surgically implanted prostheses present many attendant risks to the patient. It will suffice to say that surgeons are in need of a non-immunogenic, high tensile strength graft material which can be used for surgical repair of bones, tendons, ligaments and other functional tissue structures.
[0005] One of the most widely used anterior cruciate ligament (ACL) substitutes is the bone-patellar tendon-bone graft. The central one-third of the patient's or a donor's patella tendon, along with portions of the bony insertions of the patella tendon, is used as a replacement for the damaged ACL. The bony insertions are harvested as bone fragments to facilitate implantation and fixation of the replacement graft into osseous tunnels performed in the tibia and femur in the patient's knee joint. The bone-patellar tendon-bone graft is a popular choice for ACL reconstructive surgery because of its high load strength after six weeks and its functional bone fixation.
[0006] Some fixation devices employ various structures for coupling with a ligament or a suture and for engaging with the bone. For example, U.S. Pat. No. 5,356,435 discloses an element for fixing a ligament in a bony tunnel. The element includes an internal conduit for receiving an end of a ligament, and a clamping structure for securing the ligament end within the conduit. U.S. Pat. No. 5,356,413 to Martins et al. discloses a surgical anchor having a body portion and a suture-receiving bone. Another commonly used ACL substitute is the iliotibial band graft. The iliotibial band is a section of ligament which is harvested from a portion of a patients or a donor's iliotibial ligament located within the anterolateral ligament structures of the knee joint. The major problem with these techniques is that another part of the body, or the joint of the donor is often significantly weakened after biopsied to get grafts. Long term drawbacks of this approach are that chronic pain, patellar fractures, knee instability and cartilage degeneration.
[0007] Researchers have been attempting to develop satisfactory polymers or plastic materials to serve as ligament or tendon for other connective tissues replacements. It has been found that it is difficult to provide long-term solution using these materials to permanently replace connective tissues.
[0008] Artificial materials based on network fibers made of polyester or polytetrafluoroethylene have been used extensively as replacements for ligament and tendon, with some success. However, persistent inflammatory reactions occur following wear off of particles upon time post-implantation. Additionally, they do not readily breakdown and are not readily integrated with the body via remodeling by tissue cells.
[0009] Bioengineered tissues can be used as grafts implants or prostheses to replace damaged tissues.
[0010] U.S. Pat. No. 5,855,619 of Caplan discloses the use of a filament as load-bearing member of a contracted gel matrix containing mesenchymal cells. The implant described in this patent allows partial repair of connective tissues by attaching the implant to the tissue to be repaired. However, since this implant is constructed without anchoring extremities, the anchorage capability is limited.
[0011] Fibroblast-populated Collagen gels (FPCG) constitute an interesting in vitro model of soft tissues to investigate tissue response to various biological, chemical, electrical, and mechanical stimuli. In the past year, the potential of using a ligament-shaped FPCG to produce a bioengineered anterior cruciate ligament (ACL) has been investigated. Mechanical properties of FPCG are known, however, to be significantly lower than those required for a functional ACL. Finding ways to improve their mechanical properties would be highly beneficial not only for improving a ACL but also for the tissue engineering field in general.
[0012] It is therefore an object of the present invention to provide an implant and method of preparation thereof which obviates the disadvantages of the prior art approaches.
SUMMARY OF THE INVENTION
[0013] One object of the present invention is to provide an implant for connective tissue substitution in a human or animal, comprising a pair of bone anchors joined at their proximal ends by at least one support filament, the filament being coated by at least one matrix layer of thickness sufficient to allow for colonization by cells.
[0014] Another object of the present invention is to provide method of preparing the implant for connective tissue substitution in an animal, which comprises the steps of providing a set of bone anchors by joining a pair of bone plugs at their proximal ends by at least one support filament; and incubating at least one time the set of bone anchors in a solution containing matrix forming molecules for a period time sufficient for the formation of at least one matrix layer around the filament, the matrix layer with thickness sufficient to allow for colonization by cells, wherein the incubation is performed under condition inducing waves, vibration, cyclic traction, and/or static traction of the implant.
[0015] According to another object of the present invention, there is provided a method of preparing an implant for connective tissue substitution in an animal, said method comprising the steps of:
[0016] a) providing a set of bone anchors by joining a pair of bone plugs at their proximal ends by at least one support filament; and
[0017] b) incubating at least one time the set of bone anchors of step a) in a solution containing matrix forming molecules for a period time sufficient for the formation of at least one the matrix layer has a thickness sufficient to allow for colonization by cells, and wherein the incubation is performed under conditions in which are induced waves, vibrations, cyclic tractions, and/or static tractions of the implant.
[0018] In accordance with the present invention there is provided a matrix which is further colonized by cells. The cells may be autologous, heterologous, or cells selected from the group of fibroblast, myoblast, osteoblast, mesenchymal, endothelial, immune, chondrocyte cell, and combinations thereof.
[0019] Another object of the invention is to provide with connective tissue substitution that is partial or complete substitution of a connective tissue. The connective tissue may be selected from the group consisting of tendon, cartilage, disk, meniscus, muscle, tooth, hair, joint, ligament, and combinations thereof
[0020] Furthermore, the filament and/or matrix layer may be dehydrated or lyophilized prior to implantation.
[0021] Also in accordance with the invention, the bone anchor may be selected from the group consisting of bone portion, and piece composed of natural and/or synthetic biocompatible porous material.
[0022] The matrix layer of the invention may be composed of products selected from the group consisting of chitosan, glycosaminoglycan, chitin, ubiquitin, elastin, polyethylen glycol, polyethylen oxide, vimentin, fibronectin, derivatives thereof, and combination thereof.
[0023] Also, the filament of the present invention may be selected from the group of resorbable thread, natural fibers, and filament composed of proteins, lipids, biocompatible molecules and/or synthetic components.
[0024] The implant of the invention may further comprises a pharmaceutically effective amount of biologically active molecule selected from the group of drugs, growth factors, cytokines, antibiotics, hormones, and combination thereof.
[0025] Another object of the invention is to provide a matrix layer further comprising at least one inner layer of gel and/or filament coated by at least one supplementary matrix coating layer, or an implant comprising an inner layer of matrix and/or filament which may be dehydrated or lyophilized prior coating with the supplementary matrix coating layer. In addition, the matrix-coating layer may further comprises cells.
[0026] For the purpose of the present invention the following terms are defined below.
[0027] The term “matrix” as used herein is intended to mean a network of biological extracellular constituents, as example but without limitation collagen, elastin, fibronectin, laminine, proteoglycans, glycosaminoglycans, chitosan, ubiquitin and derivatives thereof, in a hydrated or dehydrated form. This matrix can be produced with natural fibers in combination or not with synthetic or semi-synthetic fibers.
[0028] The term “graft”, as used herein refers to a natural and/or synthetic implantable substitute for various tissue types.
[0029] The term “lyophylization” as used herein is intended to mean passive or active dehydration of hydrated matrix network as defined above. Simple air-drying, dessication, vacuum assisted dehydration, warming, water sublimation or other methods may perform the lyophylization.
[0030] The term “chemically fixed” as used herein is intended to mean fixation of treatment of matrix with a chemical, as for example but without limiting the invention, paraformaldehyde, ethanol, formaldehyde, methanol, to create link between the matrix fibers and the anchors, bones or bone substitutes.
[0031] This summary of the invention does not necessarily describe all necessary features of the invention, but that the invention may also reside in a sub-combination of these described features. The summary of the invention, thus incorporated, presents, therefore, only an example but not a limitation of subject matter to exactly this combination of features.
BRIEF DESCRIPTION OF THE DRAWINGS
[0032] [0032]FIG. 1 illustrates ligament fibroblasts (LF) isolated from a human ACL biopsy;
[0033] [0033]FIG. 2 illustrates a transverse hole made in a human bone anchor;
[0034] [0034]FIG. 3 illustrates two bone anchors liked with a surgical thread passed through their transverse holes and twisted;
[0035] [0035]FIG. 4 illustrates two sterile bone anchors readily linked by surgical thread, transferred in a sterile plastic tube and kept in position by passing a hot metal pin through their transverses holes and across tube;
[0036] [0036]FIG. 5 illustrates an ACL substitute after 24 hours in culture;
[0037] [0037]FIG. 6 illustrates an acellular ACL substitute after 24 hours in culture:
[0038] [0038]FIG. 7 illustrates an ACL substitute lyophilized;
[0039] [0039]FIG. 8 illustrates a histological section of a goat's ACL substitute before implantation. The hydrated collagen layer seeded with living LF surrounds the central circular lyophilized core;
[0040] [0040]FIGS. 9A to 9 C illustrate the collagen layer of an acellular ACL substitute consisting in a network of collagen fibers (A); the adhesion and migration of containing LF into the outer acellular hydrated collagen layer after 24 hours in culture (B); and same as in b) but after 48 hours of culture (C);
[0041] [0041]FIG. 10 illustrates the multistep procedure to prepare a substitute ligament; and
[0042] [0042]FIG. 11 illustrates an alternative multistep procedure to prepare a substitute ligament;
[0043] [0043]FIG. 12 and illustrates a macroscopic aspect of a bioengineered ACL ready for implantation (opened goat's knee joint);
[0044] [0044]FIG. 13 illustrates a macroscopic aspect of a bioengineered ACL immediately after implantation in situ (opened goat's knee joint);
[0045] [0045]FIG. 14 illustrates the macroscopic aspect of a dehydrated ligament substitute;
[0046] [0046]FIG. 15 illustrates an histological section of a dehydrated ligament substitute showing an alignment of the collagen fibers in its scaffold (longitudinal plan);
[0047] [0047]FIG. 16 illustrates an histological section of an acellular ligament substitute grafted in a goat's knee joint for 5 months; and
[0048] [0048]FIG. 17 illustrates the macroscopic aspect of a bioengineered periodontal ligament ready for implantation.
DETAILED DESCRIPTION OF THE INVENTION
[0049] The following description is of a preferred embodiment by way of example only and without limitation to the combination of features necessary for carrying the invention into effect.
[0050] In accordance with one embodiment of the invention, there is provided an implant allowing permanent implantation of a connective tissue substitute.
[0051] It is known in the art that synthetic prosthesis such as Dacron™ or lad are susceptible indirectly to wear off particles in the knee joint within a few years, leading to inflammatory reactions, cartilage degeneration and functional instability of the knee.
[0052] In one embodiment, the implant of the invention doesn't present the risks of graft rejection as it is intended to use or integrate autologous cells from the host's connective tissues, their own bone fragments and collagen.
[0053] Another important embodiment of the invention is that the use of the instant implant avoids taking any portion of healthy autologous tissues, such as a part of the patellar, semitendinous or TFL iliotibial band, or semimembranous tendons for connective tissue replacement, which often lead to chronic pain, muscular weakness or instability of the joints. Only some cells are removed from its host, defatted if necessary and processed in one of several well-known procedures used to prepare the tissue for implantation into a human, an animal, as for example but without limitation, horses, dogs and other domestic animals. The invention applies also in a general manner in the fields of veterinarian, dentistry, and orthodontic cares.
[0054] The cells useful to contract the collagen fibrils during the formation of an organized tissue-substitute implant can be obtained from various mammalian sources (e.g., bovine, porcine, human, canine). The connective tissue cells used in the method of the present invention were fibroblasts, but other mesenchymal cell types, such as fibroblasts of other sources and tissues may also be used. The human fibroblasts can be isolated by enzymatic disaggregation, explants or perfusion of the tissues of origin.
[0055] Naturally occurring cells in accordance with the present invention may include, but not limited to epithelial cells, myoblasts, chondroblasts, osteoblasts, fibroblasts, and other fibrous connective cells coming from tendon, ligament, cartilage, and the like.
[0056] Also, the autologous connective tissue cells may be conserved in a cell depository to prepare another bioengineered connective tissue implant for the patients who would break the graft under subsequent traumatic circumstances.
[0057] In accordance with another embodiment of the present invention, the procedure of implantation may be performed by arthroscopy, avoiding arthrotomies and associated risks (infection, knee pain, and loss of articular mobility, major swelling and permanent scar). These advantages contribute to reduce the cost of medical care on a long-term basis and improve life quality of the patients post-surgery.
[0058] In another embodiment, a fully functional replacement tissue is withstand at least the stresses and strains imposed by normal bodily activity on the type of tissue the construct is to replace.
[0059] Furthermore, in accordance with one embodiment of the invention, the implant is fully biocompatible and integrable, in vivo, i.e., the implant resembles a natural tissue so as to be colonized by cells and interact with these specific cells already present in the body. The colonizing cells further organize the implant and secrete specific products, such as extracellular matrix constituents, proteins and/or growth factors, within the connective tissue substitute of the present invention, enabling it to degrade, remodel and regenerate the histological structures as a functional tissue substitute. Such integration may strengthen and conditions the implant to better performs as a substitute tissue.
[0060] Yet in accordance with another aspect of the present invention, the gel layer of the implant may be supplemented with proteins, peptides, or hormones playing roles during tissue integration and tissue repair. Several known factors may be released from the implant prior implantation, as, but not limited to growth factors, growth hormones, fibroblast growth factor, epithelial growth factor, TGF-beta, insulin, and IGF-1. Cytokines may be expressed by cells genetically modified, transfected or transformed, to modulate local inflammatory processes, cartilage regeneration vascularisation, etc.
[0061] The collagen can be extracted from various collagen-containing animal tissues. Examples of possible collagen-containing tissue are tendon, skin, cornea, bone, cartilage, in vertebral disc, cardiovascular system and placenta. The collagen used herein is type I collagen. Other types of collagen (e.g., type II, III and others) may also be employed.
[0062] In accordance with the most preferred embodiment of the present invention, the matrix layer of the implant is composed of Type I collagen, but can be formed, and is not limited to recombinant collagen proteins as chitosan, chitin, ubiquitin, elastin, polyethylene oxide, vimentin, fibronectin, and combinations thereof.
[0063] According to another aspect of the invention, there is provide an implant having a pair of generally cylindrical bone plug portions joined at their proximal ends by a core filament, the bone plug preferably including both bone regions.
[0064] In another embodiment of the present invention there is to provided such an implant in which one of bone anchors is adapted to be pulled through a tunnel in, for example, the femur to allow fusion thereto and the other bone anchor portion is adapted to be pulled through a tunnel in the tibia to allow fusion thereto to provide a substitute for the natural cruciate ligament, the segment being adapted to be placed under tension between the tunnels to provide a ligament function. Similar procedures may be employed to provide connective tissue function to other bone joints.
[0065] One other embodiment of this invention is to provide a implant for promoting the healing and/or regrowth of diseased or damaged tissue structures by surgically repairing such structures with the implant of the invention. The implanted graft is trophic toward vascularization and tissue and may be essentially remodeled to assume the structural and functional characteristics of the repaired structure.
[0066] In accordance to another preferred embodiment of the invention, the implant may be lyophilized after its preparation. This process avoids the use of chemicals to strengthen the matrix layer of the implant, to allow the reinforcement of the links between the bone plugs and the collagen layer polymerized into their trabecular structure. Also, lyophylization permits the preparation of implants adding superposed matrix layers to reinforce the structure of a bioengineered connective tissue, or conferring a higher resistance to rupture before and during surgical implantation procedures.
[0067] Another important embodiment of the invention is that lyophylization may allow to form matrix layers onto the implant with other biomaterials, as for example, but not limited to elastin, in combination or not with collagen, and replacing the bone anchors of the implant by other porous anchors, as for example, but not limited to cement, or ceramic.
[0068] It is another object of the present invention to provide a graft implant which has improved graft fixation capabilities and promotes connective tissue and bone ingrowth between the graft and the bony tunnel.
[0069] In accordance with the present invention, there is provided a device and method for cyclic matrix stretching and mechanical testing. A cyclic traction machine is disclosed. In a preferred embodiment, the matrix is maintained in place in the cycling chamber by inserting the two bone anchors in metal pins, one fixed to a load cell and the other, attached to a motion controlled cursor. By controlling the position of the cursor, the matrix is subjected to cyclic traction with stretching amplitudes from 0 to 30 mm at a frequency of up to 1 Hz for lower amplitudes, for any extended period of time. The whole system is controlled via a LABview VI software. The operator may change easily the traction conditions and supervise the ongoing tests to make sure that everything is running smoothly. A set of matrix may be maintained under static tension, or subjected to a cyclic tension. The cells in a matrix as described in the present invention, may be induced to take a structural organization when submitted to tension stimulus. The stimulus may be also simply waves in a culture medium by agitation of the petri dishes in which is kept a matrix, or an electric stimulus.
[0070] The present invention will be more readily understood by referring to the following examples which are given to illustrate the invention rather than to limit its scope.
EXAMPLE I
Preparation of Anterior Crutiate Ligament
[0071] Material and Methods
[0072] LF Isolation and Culture
[0073] Torn ACL biopsies are collected from the host. The biopsies are kept at 4° C. for no longer than 24-48 hrs before cell isolation. The ACL biopsy is weighted and cut into small pieces after removal of the periligamentous tissues. The fragments are digested with 0.125% collagenase containing 2 mM CaCl 2 (1 ml of enzymatic solution/mg of tissue) for 20 hrs, under gentle agitation, at 37° C. A 0.1% trypsin solution (1 ml/mg of hydrated tissue) is then added to the cellular suspension for 1 hr. The enzymes are dissolved in Dulbecco's Modification of Eagle's™ medium (Gibco), pH 7.4, containing antibiotics.
[0074] The ligament fibroblasts (LF) isolated from ACL biopsies are cultured in DME supplemented with 10% fetal calf serum (FCS), 100 IU/ml penicillin G and 25 μg/ml gentamicin (FIG. 1).
[0075] When LF primary cultures reach about 85% confluence, the cells are detached from their culture flasks using 0.05% trypsin-0.01% EDTA solution (pH 7.8), for about 10 min at 37° C. The LF suspensions are centrifuged twice at 200×g for 10 min. The cell pellets are resuspended in complete culture medium and the cells are counted. The cellular viability is determined using the trypan blue exclusion method
[0076] Up until now, LF were isolated and cultured from ACL biopsies of more than 20 patents and 10 animals (goats, dogs, and rabbits) with 100% success. The cells maintained their morphology for more than 7 passages in culture. For ACL substitutes production, LF cultures from passages 2 to 5 are used. Immunofluorescent labeling analysis revealed that different populations of human LF extracted from ACL biopsies express vimentin, fibronectin, Types I and III collagens and elastin.
[0077] Preparation of the ACL Substitutes' Bone Anchors
[0078] Bone pieces are washed with ethanol 100% and cut in a cylindrical shape according to dimensions adapted to the needs of the host (average size of 1 cm-diam. and 2 cm-long).
[0079] A transverse hole (⅛-in. diam.) is made in each bone anchor (FIG. 2). The bone plugs are kept in 100% ethanol overnight to be sterilized. A surgical thread resorbable within 1 month post-surgery, is passed through the transverse holes of 2 bone anchors and fixed between the bones by simple stitching. Then the thread is twisted between the bones to thicken the link (FIG. 3).
[0080] A longitudinal hole or more (1 mm diam. or wider) is made in each bone anchor. Such holes are drilled in order to increase hydrated collagen adhesion with the bones. This step is optional. The 2 sterile bone plugs readily linked by the twisted surgical thread are transferred in a sterile plastic tube and kept in position by passing a hot metal pin through their transverse holes and across the tube (FIG. 4).
[0081] One of the 2 bones is fixed at the bottom and the other at the top of the tube. Then, the tube containing the bone plugs are filled with sterile culture medium containing 10% FCS and put at 37° C. overnight in order to verify that no bacterial contamination comes out. Up to now, we never had any contamination following this method. Another alternative could be that the bones and thread would be rinsed with 100% ethanol, dried under sterile conditions and sterilized a second time with ethylene oxide. They could be kept in sterile culture medium containing 5-10% FCS at 4° C. until use.
[0082] Production of the Bioengineered ACL Substitutes in vitro
[0083] Two protocols have been developed to obtain similar products; graftable bioengineered ACL substitutes. The protocol involves the addition of the living LF only at the end of the production steps, avoiding the use of cell-populated collagen gels during the.
[0084] A solution of DME 2.7X containing antibiotics is mixed with a second solution containing heat inactivated (30 min at 56° C.) FCS, solubilized bovine Type I collagen and living LF (preferably from passages 2 to 5; FIG. 10, step 3). The cells are added at a final concentration of 2.5×10 5 cells per ml but lower or higher cell concentrations could be used. The final concentration of bovine Type I collagen varies between 1.0-2.0 mg/ml in the ACL substitutes but other concentrations could be used (e.g. preferably ranging from 0.5 to 5 mg/ml). The next step is described on FIG. 10, step 5.
[0085] B) A solution of DME 2.7X containing antibiotics is mixed with a second solution containing heat inactivated (30 min at 56° C.) FCS, solubilized bovine Type I collagen. The final concentration of bovine Type I collagen varies between 1.0-2.0 mg/ml in the ACL substitutes but other concentrations could be used (e.g. preferably ranging from 0.5 to 5 mg/ml). There is yet no cell added in the mixture at this stage.
[0086] The mixture is quickly poured in the sterile plastic tube containing the 2 bone anchors linked by the twisted surgical thread.
[0087] The ACL substitute is cultured in DME supplemented with 10% FCS, 50 μg/ml ascorbic acid, 100 IU/ml penicillin G and 25 μg/ml gentamicin. It is maintained in a static vertical position during the first 24 hrs of culture mainly to allow proper collagen polymerization. The ACL substitute is then taken out of the tube after collagen polymerization (at pH 7.4). The collagen matrix is also contracted when the ACL substitute contained living LF according to procedure A (FIG. 5) but it is not contracted in the case of acellular substitutes prepared as described in procedure B (FIG. 6).
[0088] Then, the ACL substitute is taken out of the tube and frozen at −80° C. in a sterile dish (FIGS. 10 and 11, step 5).
[0089] When frozen, the ACL substitute is lyophilized (FIG. 7 and FIGS. 10 and 11, step 6).
[0090] The lyophilized ACL substitute is then transferred into a new sterile plastic tube and fixed as previously described to be used as a solid central core (FIGS. 10 and 11, step 7). Additional lyophilized layers can be added to produce larger and stronger ACL substitutes.
[0091] Another layer of hydrated collagen mixed with living LF is made and added around the lyophilized collagen core, according to the procedures described in section A. The bilayered ACL substitute can be kept in culture until grafted into the host. FIG. 8 shows a histological section of the ACL substitute before implantation (transversal plan). The central lyophilized core is surrounded by a hydrated collagen layer seeded with LF of the eventual host, in that case, a goat.
[0092] A second layer of hydrated collagen is made as described in section B (no cell is included within the matrix) The acellular ACL substitute is a network of collagen fibers (FIG. 9A). After its polymerization overnight, the acellular ACL substitute is put in culture medium containing LF suspended in the medium (DME supplemented with 10% FCS, 50 μg/ml ascorbic acid, 100 IU/ml penicillin G and 25 μg/ml gentamicin; FIG. 11, step 8). Within 24 hrs, the cells attach and migrate into the outer hydrated collagen layer (not lyophilized; FIG. 9B). The cells contract the collagen matrix while colonizing it within 48 hrs (FIG. 9C) The bilayered cell-populated ACL substitute can be kept in culture until grafted (FIG. 11, step 9). More hydrated matrix layers can be added around the bACL.
[0093] Organization of Matricial Structure Induced in the ACL Substitute by Cyclic Traction
[0094] At least 10 replicates were conducted under similar conditions to evaluate the effects of cyclic traction on the evolution of our ACL. The cycles were fixed at a frequency of 1 cycle/min. During the first 5 days, the ACL were stretched to 1-mm stretch per cycle, always returning to their initial length (about 4 cm) to complete each cycle. The amplitude was increased to 2 mm from days 5 to 10. Histologic studies were performed after 10 days on ACL cultured under static horizontal conditions compared to ACL subjected to cyclic traction. For the first time, dense network of collagen fibers organized in wavy bundles is observed in in a human bioengineered living tissue. Our data strongly show that living ACL cells seeded in ACL can respond to mechanical stimuli in vitro. The crimps followed a wavy pattern, as it is seen in native ACL. Results were repeatedly similar from one experiment to another.
[0095] Surgical Procedure for Implantation of the Bioengineered ACL Substitutes in Human and Animals
[0096] Surgical procedures are performed by arthroscopy in human and under general anesthesia in animals (intramuscular injection of ketamine and xylasine; 0.6 ml/kg body weight), maintained by inhalation of a 2:1 mixture of oxygen and nitrous oxide with 0.1% halothane.
[0097] With use of Kirschner wires and a mini-driver, a tunnel (about 1 cm diam., adapted to the knee of the host) will be created through the metaphyseal bone of the femur, distal to the epiphyseal scar and perpendicular to the long axis of the femur.
[0098] The bACL (about 1 cm length, adapted to the knee of the host) is placed within the bone tunnel, with great care to ensure that the bACL fills the entire length of the hole.
[0099] The end of the prosthesis exiting the lateral end of the tunnel is inserted in a second tunnel performed in the lateral femoral periosteum. A minimal static tension is applied on the bACL.
[0100] The bone anchors of the graft may be fixed with screws and/or cement (including biomedical epoxy).
[0101] The incision site is sprayed with a topical antibacterial agent. In the case of human, they receive a normal diet and movement restrictions during the first month post-surgery. They start to put weight on the operated leg according to tolerance and receive an exercise program to maintain or increase muscular strength. Their knees are monitored daily for a week to notice any abnormal inflammatory signs. In the case of animals, they receive a diet of water and food ad libitum. Prophylactic tetracycline is added in water for 10 days. A cast or a light orthosis presently used to limit human joint motions postsurgery is used to prevent animal knee motion over 4-7 days after bACL implantation. The animal's physical evaluation is done daily by veterinarians and their staff.
[0102] Such ligament substitute may be modified further or adapted for gene therapy by introducing genes into the cells. Also, the procedure may be easily adapted to other applications, for example, to replace a ligament at another anatomic site of the body (vertebral column, neck, etc).
EXAMPLE II
Preparation of Connective Tissues
[0103] Material and Methods
[0104] Dermal Fibroblasts Isolation and Culture
[0105] The dermal fibroblasts (DF) isolated from the dermis of skin biopsies, enzymatically (same procedure described in Example I) or by explants, are cultured in DME supplemented with 10% fetal calf serum (FCS), 100 IU/ml penicillin G and 25 μg/ml gentamicin.
[0106] When DF primary cultures reach about 85% confluence, the cells are detached from their culture flasks using 0.05% trypsin-0.01% EDTA solution (pH 7.8), for about 10 min at 37° C. The DF suspensions are centrifuged twice at 200×g for 10 min. The cell pellets are resuspended in complete culture medium and the cells are counted. The cellular viability is determined using the trypan blue exclusion method.
[0107] Up until now, the DF were isolated and cultured from skin biopsies of more than hundred patients and 10 animals (goats, dogs, and rabbits) with 100% success. The cells maintained their morphology for more than 7 passages in culture. For connective tissue substitutes production (e.g. ligaments), DF cultures from passages 2 to 5 are used.
[0108] Preparation of the Ligament Substitutes' Bone Anchors
[0109] Bone pieces are washed, cut and sterilized according to the procedure described in Example I.
[0110] Holes are made in each bone anchor, as previously described. The 2 sterile bone plugs readily linked by the twisted surgical thread are transferred in a sterile plastic tube and kept in position by passing a hot metal pin through their transverse holes and across the tube (FIG. 4).
[0111] Production of Bioengineered Ligament Substitutes in vitro
[0112] A first alternative: A solution of DME 2.7X containing antibiotics is mixed with a second solution containing heat inactivated (30 min at 56° C.) FCS, solubilized bovine Type I collagen and living DF (preferably from passages 2 to 5). The DF are added at a final concentration of 2.5×10 5 cells per ml but lower or higher cell concentrations could be used. The final concentration of bovine Type I collagen varies between 1.0-2.0 mg/ml in the ligament substitutes but other concentrations could be used (e.g. preferably ranging from 0.5 to 5 mg/ml). The next step is described in FIG. 11 step 5).
[0113] A second alternative: A solution of DME 2.7X containing antibiotics is mixed with a second solution containing heat inactivated (30 min at 56° C.) FCS, solubilized bovine Type I collagen. The final concentration of bovine Type I collagen varies between 1.0-2.0 mg/ml in the ACL substitutes but other concentrations could be used (e.g. preferably ranging from 0.5 to 5 mg/ml). There is yet no cell added in the mixture at this stage.
[0114] The mixture is quickly poured in the sterile plastic tube containing the 2 bone anchors linked by the twisted surgical thread. Collagen scaffolds are casted between two bone anchors described in example I. The tissue constructs are put into a dessicator under minimal horizontal tension, under normal atmospheric pressure or less (ranging from about 25 to 0 mm Hg). Tha appearance of the macroscopic aspect of a bioengineered ACL ready for implantation can be seen in FIG. 12, as well as immediately after implantation in situ (opened goat's knee joint) (FIG. 13). The scaffolds were completely dehydrated within about 2-3 hrs (FIG. 14). FIG. 15 shows a histological section of a collagen matrix dehydrated under these conditions.
[0115] The bioengineered scaffolds were rehydrated in fresh DMEM, taken out of the tube and then transferred into a new sterile plastic tube. Additional dehydrated layers can be added or another layer of hydrated collagen can be added containing living DF or LF, to produce larger and stronger ligament substitutes.
[0116] An acellular bioengineered ligament has been grafted into a goat's knee joint. After five months, as shown in FIG. 16, the grafted ligament is clearly colonized and innervated by the hosts' cells. Note the presence of the host's cells which colonized the graft post-implantation and the high density of collagen fibers, aligned in the long axis of the regenerating anterior cruciate ligament in situ (longitudinal plan).
EXAMPLE III
[0117] Preparation of Periodontal Ligament Substitute
[0118] Material and Methods
[0119] Fibroblasts Isolation and Culture
[0120] Dermal fibroblasts (DF), ligament fibroblasts (LF), or fibroblasts from other sources (e.g. mucosa of the mouth) can be isolated and cultured in DME supplemented with 10% fetal calf serum (FCS), 100 IU/ml penicillin G and 25 μg/ml gentamicin.
[0121] When the cells primary cultures reach about 85% confluence, they are detached from their culture flasks using 0.05% trypsin-0.01% EDTA solution (pH 7.8), for about 10 min at 37° C. The cell suspensions are centrifuged twice at 200×g for 10 min. The cell pellets are resuspended in complete culture medium and the cells are counted. The cellular viability is determined using the trypan blue exclusion method.
[0122] Preparation of the Peridontal Ligament Substitutes' Tooth Anchors
[0123] Teeth pieces are washed and sterilized according to the procedure described in Example I.
[0124] Holes are made in each tooth, as previously described. A sterile tooth is linked to a bone anchor by a twisted surgical thread and both are transferred in a sterile plastic tube and kept in position by passing a hot metal pin through their transverse holes and across the tube.
[0125] Production of Bioengineered Peridontal Ligament Substitutes in vitro
[0126] A solution of DME 2.7X containing antibiotics is mixed with a second solution containing heat inactivated (30 min at 56° C.) FCS, solubilized bovine Type I collagen and living fibroblasts (preferably from passages 2 to 5). The fibroblasts are added at a final concentration of 2.5×10 5 cells per ml but lower or higher cell concentrations could be used. The final concentration of bovine Type I collagen varies between 1.0-2.0 mg/ml in the ligament substitutes but other concentrations could be used (e.g. preferably ranging from 0.5 to 5 mg/ml).
[0127] According to a second possibility, a solution of DME 2.7X containing antibiotics is mixed with a second solution containing heat inactivated (30 min at 56° C.) FCS, solubilized bovine Type I collagen. The final concentration of bovine Type I collagen varies between 1.0-2.0 mg/ml in the ACL substitutes but other concentrations could be used (e.g. preferably ranging from 0.5 to 5 mg/ml). There is yet no cell added in the mixture at this stage.
[0128] The mixture is quickly poured in the sterile plastic tube containing the bone and the tooth anchors linked by the twisted surgical thread. Collagen scaffolds are casted between two anchors. The tissue constructs are lyophilized or put into a dessicator under minimal horizontal tension, under normal atmospheric pressure or less (ranging from about 25 to 0 mm Hg). When totally dehydrated, the scaffolds are rehydrated in fresh DMEM, taken out of the tube and then transferred into a new sterile plastic tube. Another layer of hydrated collagen can be added containing living fibroblasts, to produce larger and stronger ligament substitutes. The periodontal ligament substitute can be implanted in the gum (FIG. 17).
[0129] While the invention has been described in connection with specific embodiments thereof, it will be understood that it is capable of further modifications and this application is intended to cover any variations, uses, or adaptations of the invention following, in general, the principles of the invention and including such departures from the present disclosure as come within known or customary practice within the art to which the invention pertains and as may be applied to the essential features hereinbefore set forth, and as follows in the scope of the appended claims. | The present invention relates to connective tissue substitute implant and method of preparation thereof. The implant is essentially composed of two bone anchors joined at the proximal ends by matrix layers and/or filaments coated by supplementary biocompatible matrix coating layer which can contain living stem cells isolated from injured connective tissue. | 2 |
This is a continuation of U.S. application Ser. No. 08/061,222 filed May 13, 1993, now U.S. Pat. No. 5,466,685.
This invention relates to the chemotherapy of bacterial infections whereby a class of fatty acid ester derivatives can be utilized as inhibitors of beta-lactamase production.
BACKGROUND OF THE INVENTION
Description of the Prior Art
Beta-lactam antibiotics, such as penicillin, methicillin, amoxicillin and the like, have been used for many years in battling bacterial infections in humans. After repeated exposure to this type of antibiotic, however, many bacterial strains have become resistant to these antibiotics and now render them ineffective in treating infections. The medical and scientific community believes that bacterial resistance to beta-lactam antibiotics can usually be attributed to the ability of these bacteria to produce beta-lactamase, an enzyme that cleaves the chemical structure of the beta-lactam antibiotics.
Researchers have, therefore, approached this problem by searching for beta-lactamase inhibitors that will prevent the action of beta-lactamase and permit this class of antibiotics to remain active in treating bacterial infections. Some of these beta-lactamase inhibitors are antibacterial; some act synergistically with beta-lactam antibiotics to increase their effectiveness.
For example, U.S. Pat. No. 4,340,539 (Gottstein), entitled "Derivatives of 6-bromo Penicillanic Acid" states that 2-B-chloromethyl-2a-methylpenam-3a-carboxylic acid sulfone and salts and esters thereof are potent inhibitors of beta-lactamases. The patent states that the active derivatives of 6-bromo penicillanic acid, in conjunction with ceforanide and amoxicillin, prevent the destruction of these beta-lactam antibiotics and permit continued antibacterial activity. The active material was demonstrated to have very weak antibacterial activity by itself.
R. Baltzer, et al., in their article "Mutual ProDrugs of B-Lactam Antibiotics and B-Lactamase Inhibitors," J. Antibiotics 33(10), 1183-1192 (1980) describes the combination of a beta-lactam antibiotic with a beta-lactamase inhibitor in a single molecule functioning as a pro-drug for the two active components. A beta-lactamase inhibitor, penicillanic acid sulfone, was combined with ampicillin and mecillinam. The article states that, in humans, these esters are absorbed from the gastrointestinal tract and, after absorption, are hydrolyzed with liberation of the active components.
U.S. Pat. No. 4,377,590 (Myers), entitled "Derivatives of Ampicillin and Amoxicillin with Beta-Lactamase Inhibitors" describes certain antibiotics having beta-lactamase inhibitors. These antibiotics contain a beta-lactam ring, as well as a carboxy group located on either the amino group of ampicillin, the amino group of amoxicillin, or the phenolic hydroxy group of amoxicillin.
European Patent Publication EP 0023 093 A1 (Harbridge), entitled "Pencillanic Acid Derivatives, Their Preparation and Use in Pharmaceutical Compositions" relates to pharmaceutical compositions containing penicillin or cephalosporin. The publication states that a class of penicillanic acid derivatives having antibacterial activity possess the ability to enhance the effectiveness of penicillin and cephalosporins.
British Patent No. 1,573,503 (Cherry, et al.), entitled "Ethers of (2)-hydroxy-ethylidene-clavam-(3)-carboxylic acid--Useful Antibiotics, Beta-lactamase Inhibitors and Intermediates" relates to ethers of clavulanic acid and their salts and esters. These compounds can be utilized as antibiotics or as beta-lactamase inhibitors. The patent states that these compounds have some antibiotic activity and are stable to the action of beta-lactamases. The patent also states that the compounds inhibit beta-lactamase enzymes.
WO 9117995 (Altamura, et al.) describes penem dithiocarbamate derivatives as beta-lactamase inhibitors for use of antibacterial agents and antibiotics. EP 212404 (Cooke, et al.) describes 2-phenyl-2-penem-3-carboxylic acid derivatives as being antibacterial agents and antibiotics. WO 8700525 (Broom, et al.) describes 6-heterobicyclic-methylene-penem-3-carboxylic acid compounds which are both antibacterial and possess beta-lactamase inhibitory activities.
Thus, research activities to date in the area of retaining the activity of beta-lactam antibiotics have focused on efforts to neutralize or inactivate beta-lactamase enzymes after they are formed. There has been little or no attention directed to preventing the formation of beta-lactamase enzymes by any means.
Of course, the ability to inhibit the formation of beta-lactamase enzymes is extremely desirable as this process would permit a larger proportion of beta-lactam antibiotics to be effective, without interference from the beta-lactamase enzymes.
SUMMARY AND OBJECTS OF THE PRESENT INVENTION
Thus, it is an object of this invention to provide a means for preventing the formation of beta-lactamase enzyme by bacteria.
It is a further object of this invention to provide a method by which to render bacteria sensitive to beta-lactam antibiotics.
Additional objects of this invention will become evident in accordance with the following discussion.
In accordance with the present invention, it has been discovered that certain esters of polyhydric aliphatic alcohols and fatty acids unexpectedly inhibit bacterial production of beta-lactamase. It is believed that such esters interfere with the transcription of the beta-lactamase blaZ gene and hence the expression of betalactamase enzyme by Staphylococcus aureus bacteria (hereinafter, "S. aureus"). Esters for this purpose are formed from fatty acids with eight to eighteen carbon atoms and polyhydric alcohols, wherein said ester has at least one hydroxyl substituent on its aliphatic alcohol residue. These esters are used in conjunction with beta-lactam antibiotics. Preferably, monoesters and diesters or mixtures of monoesters and diesters of a polyhydric aliphatic alcohols and a fatty acid having from eight to eighteen carbon atoms are used.
We theorize that when the compositions of this invention contact bacterial cells, they adversely affect the signal transduction function of the cell, thus inhibiting the expression of beta-lactamase at the level of transcription in the bacteria. In the case of beta-lactamase production in Staphylococci, the method of production is believed to be by a signal transduction pathway as described in Bacillus licheniformis by Y. Zhu, S. Englebert, B. Joris, J. M. Ghusen, T. Kobayashi and J. O. Lampen, in an article entitled "Structure, Function and Fate of the blaR signal transducer involved In Induction of Beta--lactamase In Bacillus licheniformis" in J. Bacteriology, Oct. 1992.174 (19), p. 6171-8. This pathway is analogous in Staphylococci based on amino acid similarity as reported by Wang, et al., Nucleic Acids Review, Vol. 19, p. 4000, 1991.
In general, signal transduction is the process by which gene expression is regulated in response to environmental signals. The bacterial cell often must adjust to changes in its external environment. In order to adjust to these changes, bacteria may have to respond by expressing a particular gene or group of genes or alternatively, turning off the expression of a gene or a group of genes. Therefore, the cell must have a means by which information about its environment is transmitted from the outside of the cell to the inside of the cell, accomplished by a process which is referred to as "signal transduction".
The signal which triggers beta-lactamase production in Staphylococci is beta-lactam-containing compounds such as penicillin. Under normal circumstances, beta-lactamase is not manufactured by the bacteria. The bacteria's failure to manufacture this compound under normal circumstances can be attributed to the inhibition of expression of the gene which encodes this protein (blaZ), i.e., the prevention of transcription of the gene. It is thought that BlaI inhibits the blaZ gene.
When bacteria are exposed to a beta-lactam compound, the beta-lactam compound becomes attached to the bacterial cell transmembrane receptor protein (BlaR1). The attachment to the BlaR1 protein initiates a cascade of events which are as yet not wholly understood, but which result in relieving the transcriptional inhibition of the blaZ gene by the BlaRI protein.
Signal transduction has historically been reported not only in Bacillus licheniformis but in Salmonella typhimurium as well, (K. Hannary, et al., "TonB Protein of Salmonella Typhimurium A Model for Signal Transduction Between Membranes," J. Mol. Biol. (1990) 216, 897-910. This article proposes a model whereby TonB serves as a "mechanical" linkage that acts as a means of coupling energy to outer membrane transport processes. This mechanism as described by Hannary, et al. has implications for signal transduction within and between proteins. This work was accomplished using TonB--beta-lactamase fusions.
In the article "Coordinate Regulation of Beta-lactamase Induction and Peptidoglycan Composition by the amp Operon," (E. Tuomanen, et al., Science, Vol. 251, p. 201-203 (1991), the authors suggest that beta-lactamase induction and modulation of the composition of the cell wall share elements of a regulatory circuit that involves AmpD. E. coli requires AmpD to respond to extracellular signalling by amino acids and this signal transduction system may regulate peptidoglycan composition in response to cell wall turnover products.
Previous signal transduction studies have focused predominantly on altering and/or blocking specific receptor sites on the trans-membrane receptors. However, the compositions of the present invention apparently affect signal transduction through the cell membrane in a non-specific manner and block several signal transduction pathways simultaneously. Specifically, the compositions of this invention inhibit transcription of the blaZ gene, thereby inhibiting production of blaZ messenger RNA ("mRNA"). This, in turn, precludes the translation of the information necessary to make the beta-lactamase protein. The result of this phenomenon is that the bacterial cell produces no beta-lactamase and, therefore, remains susceptible to beta-lactam antibiotics such as penicillin, methicillin, amoxicillin and the like.
The fatty acid portion of the aforementioned monoesters and diesters may, preferably, be derived from caprylic, capric, lauric, myristic, palmitic and stearic acids, which are saturated fatty acids whose chain lengths, respectively, are C8, C10, C12, C14, C16 and C18. The fatty acid portion of the aforementioned monoesters and diesters may be derived as well from unsaturated fatty acids having carbon chain lengths also ranging from C8 to C18. One example of such unsaturated fatty acids is oleic acid. Most preferably, the fatty acid is lauric acid, a saturated fatty acid whose chemical formula is C 11 H 23 COOH.
As used in this specification and the appended claims, the term "aliphatic" has the meaning usually accorded it in the field of organic chemistry, i.e., "aliphatic" refers to organic compounds characterized by straight or branched chain arrangement of the constituent carbon atoms.
As used in this specification and the appended claims, the term "polyhydric" refers to the presence in a chemical compound of at least two hydroxyl (OH) groups. Thus, a polyhydric aliphatic alcohol is one which has at least two hydroxyl groups and in which the carbon backbone is either straight or branched.
Polyhydric alcohols suitable for forming monoesters and/or diesters for use in the practice of the present invention are 1,2-ethanediol; 1,2,3-propanetriol(glycerol); 1,3-propanediol; 1,4-butanediol; 1,2,4-butanetriol and the like. The preferred polyhydric aliphatic alcohol for forming monoesters and diesters for use in the compositions of this invention is 1,2,3-propanetriol, commonly called glycerol, whose formula is HOCH 2 CH(OH)CH 2 OH.
Preferably, the esters which are useful in the practice of this invention have at least one hydroxyl group associated with their aliphatic alcohol residue. Thus, it will be understood that the monoester of 1,2-ethanediol and one of the aforementioned fatty acids may be used in the practice of this invention because said ester, whose general formula is: ##STR1## has at least one hydroxyl group (i.e., the hydroxyl group at the far right-hand side of the structural formula shown above) in that portion of the ester derived from the aliphatic alcohol 1,2-ethanediol. On the other hand, it will be understood that the diester of 1,2-ethanediol and one of the aforementioned fatty acids are preferably not used in the practice of this invention because said ester, whose general formula is: ##STR2## does not have at least one hydroxyl group in that portion of the ester derived from the 1,2-ethanediol.
The monoester of glycerol and one of the designated fatty acids is particularly useful in the practice of this invention because that ester has two hydroxyl groups associated therewith which are derived from the glycerol. The diester of glycerol and one of the designated fatty acids may also be used because that ester will have one hydroxyl group associated therewith which is derived from the aliphatic alcohol glycerol. Indeed, blends of glycerol monolaurate and glycerol dilaurate have been found to be useful in the practice of this invention. It will be understood that the triester of glycerol and one of the designated fatty acids is not useful in the practice of this invention because that ester does not have at least one hydroxyl group in the portion thereof which is derived from the aliphatic alcohol, i.e., glycerol.
Preferred esters for use in the practice of this invention are glycerol monolaurate, glycerol dilaurate and mixtures thereof.
BRIEF DESCRIPTION OF THE DRAWINGS
The foregoing features of the present invention may be more fully appreciated in the context of a detailed discussion thereof taken in conjunction with associated Figures thereto, of which:
FIG. 1 depicts a graph representing direct tests for the inhibition of toxin production in conjunction with a preferred composition of this invention; and
FIG. 2 depicts a graph demonstrating the effect of a preferred composition of this invention upon the production of betalactamase by S. aureus bacteria.
DESCRIPTION OF THE INVENTION
In the course of investigating the mechanism by which glycerol monolaurate ("GMU") and its related compounds prevents the formation of TSST-1 toxin by S. aureus, as set forth in U.S. Continuation-in-Part patent application Ser. No. 717,168, entitled "Additives To Tampons", filed Jun. 17, 1991, corresponding to parent U.S. patent application Ser. No. 343,965, filed Apr. 27, 1989, it was unexpectedly found that placing a fatty acid ester compound according to this invention in contact with beta-lactamase-producing S. aureus inhibited the production of beta-lactamase in the presence of a beta lactam antibiotic, i.e., the signal that prompts the bacteria to produce beta-lactamase.
Three different pathways regulating exoprotein production in S. aureus are known or thought to involve transmembrane signaling. Two of these are global regulator pathways, namely: (1) agr (Kornblum, et al., "Molecular biology of the staphylococci," VCH Publishers, New York, 1990 and Morfeldt, et al., Mol. Gen. Genet., Vol. 211, p. 435, 1988) and (2) a post exponential phase signal (Vendenesch, et al., J. Bacteriol., Vol. 173, p. 6313, 1991). These global regulators are jointly required for the transcriptional activation of many exotoxin genes. The third pathway is the classical beta-lactamase induction pathway (Novick, J. Gert. Microbiol., Vol. 33, p. 121, 1963; Grossman, et al., Febs. Lett., Vol. 246, p. 83, 1989; Grossman, et al., Nucleic Acids Res., Vol. 15, p. 6049, 1987; Wang, et al., Nucleic Acids Res., Vol. 19, p. 4000, 1991; Wang, et al., J. Bacteriol., Vol. 169, p. 1763, 1987).
Agr activation is thought to involve signal transduction, on the basis of a resemblance between the predicted products of two of the agr genes, agrA and agrB, and the two components of the classical signal transduction pathways in bacteria (Kornblum, et al., 1990). The activating signal is not known, however, nor has transmembrane signalling been demonstrated for this system. The temporal signal is known, thus far, only as a physiological signal that is independently required for post exponential phase activation of exotoxin gene transcription. Beta-lactamase is indifferent to either of these global systems.
The best understood of the three systems is beta-lactamase induction, a bona fide signal transduction pathway. This pathway is activated by the binding of a beta-lactam structure to the transmembrane penicillin binding protein, BlaR1, conserved among gram positive bacteria (Wang, et al., 1991). This binding initiates a signal which ultimately relieves repression of the beta-lactamase promoter by BlaI, a classical repressor (Grossman, et al., 1989). Relieving the repression permits the formation of beta-lactamase.
Direct tests for the inhibition of signal transduction by the most preferred fatty acid ester, glycerol monolaurate ("GML"), were performed on the agr and beta-lactamase systems. These tests revealed that GML had no significant effect on the activation of agr transcription, whereas it completely blocked the induction of beta-lactamase. A graph of these test results is set forth in FIG. 2.
Moreover, this latter effect was specific for induction, as GML had no effect on the constitutive synthesis of beta-lactamase by blaI mutants. Preferably, in order to obtain the full effect of GML, the inhibitor (GML) should be added at least thirty minutes prior to the inducer (antibiotic). If the two were added simultaneously, only partial inhibition was seen. Although these results implicate transmembrane signal transduction as the target of GML inhibition of beta-lactamase induction, they do not reveal the particular target for exotoxin inhibition. A possible clue can be gleaned from experiments similar in nature to that shown in FIG. 1, in which GML inhibition of alpha-hemolysin synthesis was demonstrated. In particular, the residual alpha-hemolysin synthesis seen with an agr - mutant was inhibited as fully as that seen with an agr + wild type (not shown). This result is consistent with the implication that the GML-sensitive step in exotoxin synthesis is not agr and it indicates either that the temporal signal is the target or that there is some other unknown exotoxin regulation system or systems regulating exotoxin synthesis.
The inventors hypothesize that GML and its related fatty acid esters of polyhydric alcohols may inhibit signal transduction by intercalating into the cytoplasmic membrane and subtly modifying membrane structure so as to interfere with the conformational shifts in the structure of transmembrane proteins by which signals are projected through membranes. It is also possible that GML inhibits ligand binding. Effects on cytoplasmic elements of the signal transduction pathway are less likely because of the nature of the inhibitor.
EXAMPLE
Brain Heart Infusion ("BHI") Broth (Difco) was used as a growth medium. Glycerol monolaurate (Monomuls 90 L-12, manufactured by Henkel Corporation) was prepared at a concentration of 1% w/v in 95% ethanol. Cultures to be used as inocula were grown at 37° C. overnight without shaking in a 300 ml baffled, side arm, shaker flask having a volume of 10 ml. Ten ml of additional medium was added to the culture and the flasks were shaken at 240 rpm for one hour. The resulting, exponential phase culture was then subcultured by addition of 1.0 ml into 20 ml total in a side arm, 300 ml shaker flask and frown at 37° C. with shaking at 240 rpm. Growth was monitored turbidimetrically using a Klett-Sumerson photoelectric colorimeter with a green filter.
The S. aureus strains used were as follows: RN11 is a derivative of S. aureus strain NTCC 8325 carrying pI258 (a naturally occurring beta-lactamase plasmid). Beta-lactamase production is inducible in this strain. RN24 is similar to RN11 except that the resident plasmid in RN24 is a mutant pI258 which has a mutation in the blaI gene rendering the strain a constitutive, high level producer of beta-lactamase.
Beta-lactamase producing S. aureus strains RN11 (inducible) and RN24 (constitutive) were grown in Brain Heart Infusion Broth as described above. Cells in log phase were subcultured 1:20 at time zero. Four separate RN11 cultures were followed and beta-lactamase production monitored and recorded as set forth in FIG. 2:
1. A culture grown without GML (represented by a circle);
2. A culture grown without GML induced at 75 minutes of growth with 4 μg/ml of carboxybenzyl aminopenicillanic acid (CBAP), a gratuitous inducer of beta-lactamase (represented by a square);
3. A culture grown with GML (conc.: 20 μg/ml) added at time zero and induced with CBAP at 75 minutes of growth (represented by a triangle);
4. A culture grown with GML (conc.: 20 μg/ml) and CBAP added simultaneously at 75 minutes of growth (represented by a diamond); and
5. A fifth culture with the constitutive blaI mutant of pI258 (RN24) was grown in the same manner as RN11 with GML (conc.: 20 μg/ml) added at time zero and CBAP added at 75 minutes (represented by a plus sign).
Samples were taken at the indicated time points and beta-lactamase activity was determined as described in C. H. O'Callaghan, et al., Antimicrob. Agents Chemother. 1, 283 (1972) and normalized to total cell mass.
The results of this example are depicted graphically in FIG. 2. Direct tests for GML inhibition were performed on the agr and beta-lactamase systems and these revealed that GML had no significant effect on the activation of agr transcription (not shown). However, GML completely blocked the induction of beta-lactamase. Moreover, this latter effect was specific for induction as GML had no effect on the constitutive synthesis of beta-lactamase by blaI mutants. It should be noted that the full effect of GML was seen only if the inhibitor was added at least 30 minutes prior to the inducer. If the two were added simultaneously, only partial inhibition was seen. Although these results implicate trans-membrane signal transduction as the target of GML inhibition, they do not reveal the particular target for exotoxins.
FIG. 2, therefore, shows that when GML is added to a culture of a strain of Staphylococcus aureus, which inducibly produces beta-lactamase prior to addition of an inducer of beta-lactamase (CBAP--carboxybenzyl aminopenicillanic acid) that culture is inhibited for production of beta-lactamase. This result is depicted by the triangle. Addition of both GML and inducer simultaneously gives an intermediate level of inhibition, as shown by the diamonds. Addition of CBAP to a culture that is not treated with GML gives "full induction," as depicted by the open boxes. Failure to add inducer also results in no production of beta-lactamase, as depicted by the open circles. A culture defective in the beta-lactamase inhibitor gene BlaI produces beta-lactamase constitutively (i.e., at all times) and is not inhibited by GML, as indicated by the plus signs. Thus, we conclude that GML is acting at the level of signal transduction to prevent the induction of the transcription of beta-lactamase.
The in vivo activity of a beta-lactam antibiotic in combination or in conjunction with a fatty acid ester of glycerol is suitable for the control of bacterial infections in mammals including humans. They are administered orally, parenterally or transdermally, by infusion, or in combinations thereof. These compounds are useful in the control of infections caused by susceptible bacteria in human and animal subjects.
When the active compound combination of this invention is administered and comes into contact with susceptible bacteria, the fatty acid ester of glycerol or salts of fatty acid esters of a glycerol should inhibit the ability of the bacteria to produce beta-lactamase, thus leaving the beta-lactam antibiotic active to kill the susceptible bacteria. Thus, the compounds specified herein can be utilized in a 1:1 mixture or equally effective concentration combination of the fatty acid ester of glycerol to beta-lactam antibiotic. Final effective concentration of fatty acid ester of glycerol of 3-30 μg/ml and standard administered dose of beta-lactam antibiotic from 500 to 4000 mg or an equally effective dose. The beta-lactam antibiotic should be utilized in an amount effective to provide antibiotic activity to the person to whom it is administered.
When using an antibacterial compound combination of this invention in a mammal such as man, the compound combination comprising the fatty acid ester of glycerol and the beta-lactam antibiotic, either compound could be administered alone or mixed with pharmaceutically-acceptable carriers or diluents. Said carrier or diluent is chosen on the basis of the intended mode of administration. For example, when considering the oral mode of administration, a beta-lactam antibiotic plus fatty acid ester of glycerine can be administered in the form of tablets, capsules, lozenges, syrups, elixirs, aqueous solutions and/or suspensions and the like in accordance with standard pharmaceutical practice. The proportional ratio of active ingredient to carrier will depend on the chemical nature, solubility and stability of the active ingredient as well as dosage contemplated. Another aspect of such formulations which should be taken into account is whether the compounds used therein are hydrolyzed or digested by various enzymes in the body.
For parenteral administration, which includes intramuscular, intraperitoneal, subcutaneous and intravenous use, sterile solutions of the active ingredients are usually prepared, and the pH of the solutions are suitably adjusted and buffered. For intravenous use, the total concentration of solutes should be controlled to render the preparation isotonic.
A third mode of administration is in a pharmaceutically acceptable carrier, with the active ingredient administered transdermally.
The antibiotic fatty acid ester combinations of this invention are of use in human and animal subjects and the daily dosages to be used will not differ significantly from other, clinically-used beta-lactam antibiotics such as penicillin, methicillin, amoxicillin, cephalosporin, oxacephalosporin, carbacephalosporin, carbapenem, penem, monobactam, and clavam. The prescribing physician will ultimately determine the appropriate dose for a given human subject and this can be expected to vary according to the age, weight, and response of the individual patient as well as the nature and severity of the patient's symptoms.
The above-described arrangement is merely illustrative of the principles of the present invention. Numerous modifications and adaptations thereof will be readily apparent to those skilled in the art without departing from the spirit and scope of the present invention. | A class of chemical compounds comprising fatty acid ester derivatives used to inhibit beta-lactamase production by infectious bacteria. These inhibitors have been found to retard the resistance of certain strains of bacteria to beta-lactam antibiotics, such as penicillin, by interfering with the transcription of the beta-lactamase gene and precluding expression of beta-lactamase. In accordance therewith, these inhibitors permit effective treatment of infections of otherwise resistive bacteria with antibiotics. | 0 |
This is a continuation of application Ser. No. 08/264,574 filed Jun. 23, 1994 now abandoned.
FIELD OF THE INVENTION
This invention relates to white conductive powders for use in electrically conductive or antistatic synthetic fibers, as well as in plastics and paints protected against static buildup. The invention also relates to a process for producing such white conductive powders, as well as resin compositions containing them.
Many of the currently used conductive or antistatic synthetic fibers, plastics and paints are formulated with carbon black, metal powders, etc. However, the black color of these constituent materials has limited the use of the final products. With a view to solving this problem, there have been proposed white conductive powders that comprise the particles of titanium dioxide, etc. coated with an antimony-doped tin oxide layer (see, Japanese Patent Public Disclosure (KOKAI) Nos. Sho 53-92854, 58-209002, etc.), as well as synthetic fibers, plastics and paints that are formulated with such white conductive powders (see, Japanese Patent Public Disclosure (KOKAI) Nos. Sho 56-169816, Hei 2-307911, etc.)
The synthetic fibers, plastics and paints that have the proposed white conductive powders added thereto have a much higher degree of whiteness than those formulated with carbon black, metal powders and other conventional materials. Yet, compared to the case of formulating titanium dioxide which is one of the most commonly used white pigments, the color of those synthetic fibers, plastics and paints is bluish black and still low in whiteness. As a further problem, the color of the antimony-doped tin dioxide changes to bluish black upon exposure to light, causing color shading in the surfaces of resins and paints that incorporate said antimony-doped tin dioxide.
Powders that are free from the problem of discoloration under light can be prepared by doping zinc oxide with aluminum (the product is called "conductive zinc oxide"). Resins and paints that are formulated with this conductive zinc oxide are preferable in that they experience only limited discoloration under light; on the other hand, they are inferior in conduction characteristics compared to conductive powders such as those of TiO 2 coated with antimony-doped tin dioxide; for example, their volume resistivity is about a hundred times as high as the value of "conductive titanium dioxide" powder. In addition, they have not been completely satisfactory in terms of whiteness.
Further, the toxicity of antimony is much discussed today and the use of antimony-free white conductive powders is on great demand.
Japanese Patent Public Disclosure No. Hei 4-154621 has proposed a non-antimony method but this is unable to produce a powder that has a comparable volume resistivity to antimony-containing powders.
Japanese Patent Public Disclosure No. Sho 61-141618 proposed potassium titanate coated with tin dioxide-containing indium oxide. However, to prepare this powder, an aqueous solution of indium chloride and an ethanol solution of stannous chloride were used separately and the failure to provide uniform coating ratios for the two compounds presented the problem of unstable volume resistivities. Further, the surfaces of substrate potassium titanate particles were coated only poorly with indium oxide and the substrate worked as an impurity to lower the conductivity of the coating layer. Hence, despite the increase in the coverage with tin oxide-containing indium oxide, the powder had a volume resistivity as high as 10 4 Ω·cm.
Japanese Patent Public Disclosure No. Sho 60-253112 proposed muscovite coated with tin dioxide containing indium oxide. However, as in the case of the above-described potassium titanate, the coverage with tin dioxide-containing indium oxide was poor and this problem, coupled with the adverse effect of the substrate, required increasing the coverage with tin dioxide-containing indium oxide.
The same problems have been encountered in other prior art white inorganic pigment particles; it was difficult to achieve a uniform coat of tin dioxide-containing indium oxide and the failure to lower the volume resistivity due to the adverse effect of the substrate inorganic pigment particles made it impossible to produce white conductive powders having good conduction properties.
SUMMARY OF THE INVENTION
An object, therefore, of the present invention is to provide a white conductive powder that retains the good conduction properties of the conventional conductive powder coated with antimony-doped tin dioxide, as well as the high photo-stability of the conductive zinc oxide and which yet has a degree of whiteness comparable to that achieved by using common pigment-quality titanium dioxide.
Another object of the invention is to provide a resin composition containing the novel white conductive powder.
The present inventors conducted intensive studies in order to develop resin compositions that satisfied the requirements mentioned above and the present invention has been accomplished on the basis of these studies. Briefly stated, the invention provides, in one aspect, a white conductive powder that comprises white inorganic pigment particles the surfaces of which are coated with a conductive layer consisting of a lower tin dioxide sub-layer and an upper tin dioxide-containing indium oxide sub-layer. The invention provides, in another aspect, a white conductive composition having said white conductive powder Incorporated in a resin component.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a transmission electron micrograph (×120,000) showing the structure of particles in the white conductive powder prepared in Example 1; and
FIG. 2 is a transmission electron micrograph (×120,000) showing the structure of particles in the white conductive powder prepared in Comparative Example 1.
DETAILED DESCRIPTION OF THE INVENTION
The white conductive powder according to the first aspect of the invention is prepared by a process comprising the steps of coating the surfaces of white inorganic pigment particles uniformly with 0.5-50 wt % of a tin dioxide hydrate as SnO 2 on the basis of the pigment, then applying an overcoat of 5-200 wt % of an indium oxide hydrate as In 2 O 3 on the basis of the pigment, said indium oxide hydrate containing 0.1-20 wt % of a tin dioxide hydrate as SnO 2 , and finally heating the thusly coated pigment particles in a non-oxidizing atmosphere at 350°-750° C.
The white inorganic pigment particles serving as the substrate of the white conductive powder of the invention may be of any commercial type selected from among titanium dioxide, aluminum oxide, silicon dioxide, zinc oxide, barium sulfate, zirconium oxide, alkali metal salts of titanic acid and muscovite. To take the particles of titanium dioxide as an example, their size is in no way limited and they may be spherical, acicular or in any other morphologies, and they may be anatase, rutile or even amorphous. While the present invention is primarily intended for use with white pigments but it should be noted that the inventive concept is also applicable to iron oxide and various other color pigments.
Before going into details of the invention, let us briefly explain the history to the development of the novel white conductive powder.
With a view to imparting conductivity to white inorganic pigments, the inventors first tried a method in which the surfaces of the particles were coated directly with an indium oxide hydrate containing a tin dioxide hydrate. However, this method was incapable of forming a uniform indium oxide hydrate coat over the surfaces of inorganic pigment particles and, in addition, the substrate pigment particles prevented themselves from being imparted good conductivity even when they were subjected to a heat treatment. To solve these problems, the inventors continued their studies and tried a process in which the surfaces of substrate inorganic pigment particles were first coated with a hydrate of a metal oxide such as zinc oxide or zirconium oxide which are conventionally used as coating materials and subsequently applied an overcoat of an indium oxide hydrate containing a tin dioxide hydrate. To their great surprise, the resulting coat was found to be uniform by examination with a transmission electron microscope. However, those metal oxides were still unsatisfactory in assuring good conductivity under the effects of the primer hydrate. The inventors then used a tin oxide hydrate in the primer coat and found that the resulting powder showed very good conduction properties without being effected by the substrate inorganic pigment particles or the primer tin oxide hydrate. The present invention has been accomplished on the basis of this finding. It should be noted here that the tin dioxide hydrate coat as the lower sub-layer may contain a small amount of indium oxide hydrate to the extent that will not impair the intended advantages of the invention.
The process for producing the white conductive powder of the invention is described below in detail.
The tin dioxide hydrate coat as the lower sub-layer can be formed by various methods, for example, by first adding a solution of a tin-salt or a stannate to an aqueous suspension of white inorganic pigment particles and then adding an alkali or an acid, or by adding a tin salt or a stannate and an alkali or an acid simultaneously for coating purposes. To insure that a tin oxide hydrate is coated uniformly over the surfaces of the white inorganic pigment particles, the method of simultaneous addition is more suitable. When adopting this approach, the aqueous suspension of pigment particles is preferably kept heated at 50°-100° C. For simultaneous addition of a tin salt or a stannate and an alkali or an acid, the pH is typically adjusted between 2 and 9. Since the tin dioxide hydrate has an isoelectric point at a pH of 5.5, it is important and preferable that the pH of the aqueous suspension be maintained at 2-5 or 6-9 and this insures that the hydration product of tin is deposited uniformly over the surfaces of the white inorganic pigment particles.
Exemplary tin salts that can be used include tin chloride, tin sulfate and tin nitrate. Exemplary stannates that can be used include sodium stannate and potassium stannate.
Exemplary alkalies that can be used include sodium hydroxide, potassium hydroxide, sodium carbonate, potassium carbonate, ammonium carbonate aqueous ammonia and ammonia gas; exemplary acids that can be used include hydrochloric acid, sulfuric acid, nitric acid and acetic acid.
The coating weight of the tin dioxide hydrate should be 0.5-50 wt %, preferably 1.5-40 wt % as SnO 2 on the basis of the substrate white inorganic pigment. If the coating weight is less than 0.5 wt % as SnO 2 , a tin oxide-containing indium oxide hydrate cannot be applied to form a uniform overcoat and, furthermore, the effect of the substrate inorganic pigment particles becomes significant to increase the volume resistivity of the resulting powder. If the coating weight of the tin dioxide hydrate exceeds 50 wt % as SnO 2 , an increased amount of the tin oxide hydrate will fail to adhere closely to the surfaces of the substrate inorganic pigment particles and the resulting coat tends to be non-uniform.
The upper sub-layer, or the coating of tin dioxide-containing indium oxide hydrate, can also be formed by various methods. However, in order to assure that the previously formed tin dioxide hydrate coat will not be dissolved, it is preferable to adopt a method in which a mixed solution of a tin salt and an indium salt is added simultaneously with an alkali for coating purposes. If this approach is taken, the aqueous suspension of pigment particles is preferably warmed at 50°-100° C. For simultaneous addition of the mixed solution and an alkali, the pH is typically adjusted between 2 and 9. Again, it is important and preferable to maintain the pH at 2-5 or 6-9 and this insures that the hydration products of tin and indium are deposited uniformly over the surfaces of the white inorganic pigment particles.
Starting tin materials may be selected from among tin chloride, tin sulfate, tin nitrate, etc. and starting indium materials may be selected from among indium chloride, indium sulfate, etc.
Tin dioxide should be added in an amount of 0.1-20 wt %, preferably 2.5-15 wt %, as SnO 2 on the basis of In 2 O 3 . The desired conductivity cannot be attained if the addition of tin dioxide is less than 0.1 wt % or greater than 20 wt % as SnO 2 .
Indium oxide should be added in an amount of 5-200 wt %, preferably 8-150 wt %, as In 2 O 3 on the basis of the substrate inorganic pigment particles. If the addition of indium oxide is less than 5 wt %, the desired conductivity cannot be attained. Even if the addition of indium oxide is greater than 200 wt % as In 2 O 3 , little improvement in conductivity is achieved and, on the contrary, the production cost is increased to cause diseconomy.
The term "conductive powder" as used herein means those powders which have volume resistivities of 1-500Ω·cm. As will be demonstrated in the examples that are given later in this specification, the present invention enabled the production of white conductive powders which, in terms of volume resistivity, were comparable to the conventional antimony-containing product (≦100Ω·cm) or even better than the later (≦10Ω·cm).
The heat treatment is preferably conducted in a non-oxidizing atmosphere at 350°-750° C. Heat treatment in a non-oxidizing atmosphere is effective in reducing the volume resistivity of powders by two or three orders of magnitude compared to the products heat treated in air.
The non-oxidizing atmosphere can be created by using an inert gas such as nitrogen, helium, argon or carbon dioxide. For industrial practice, the heat treatment may be performed with nitrogen gas being blown and this is not only economical but also instrumental to the production of conductive powders with consistent characteristics.
The heating temperature is generally in the range from 350° to 750° C., preferably from 400° to 700° C. The desired conduction characteristics are difficult to attain if the temperature is lower than 350° C. or higher than 750° C. If the heating time is too short, no effect is achieved by heating; if the heating time is unduly long, no commensurate increase in effectiveness will occur. Hence, the heating time is suitably in the range from about 15 min to about 4 h, preferably from about 1-4 h.
Any resin components can be used in the invention as long as they are commercial synthetic fibers, plastics, paints and other products that need be furnished with conductivity. Specific examples of the resins that can be used include polyalkyl resins such as polyethylene, polyvinyl resins such as polyvinyl chloride, polyester resins, nylon resins, acrylic resins, ABS resins, phenolic resins, urethane resins, silicone resins, epoxy resins, alkyd resins, melamine resins. The applicable resins may be thermoplastic or thermosetting. Mixtures of the above-listed resins, as well as halogen-substituted resins can also be used.
To produce conductive resin compositions, the resin component to be modified may be compounded with the white conductive powder by a suitable means such as a twin-screw kneader or hot rollers. Alternatively, a sand grinder or the like may be used to prepare a resin paint containing the white conductive powder, which paint is then coated onto a substrate to form a thin conductive or antistatic film. Since the conductive powder has a high degree of whiteness, a bright colored, conductive resin composition can be produced by using this powder In combination with colored pigments or paints.
If the use of conductive or antistatic fibers is intended, they may be formulated from compositions that have been produced by compounding the conductive powder into resins and this is preferable from the viewpoint of manufacturing practices or physical properties. If the purpose of using conductive resin compositions is to prevent static buildup on films, resin-made containers, wall materials, etc., the application of resin paints is preferred since this permits easy production at low cost.
The white conductive powder to be incorporated varies with the process for producing the intended conductive resin composition or with the desired conductivity and, hence, it need be adjusted in accordance with the specific use. If the composition is to be used for the purpose of preventing static buildup, it should not have a surface resistance higher than 10 8 Ω/cm and this necessitates incorporating the white conductive powder in an amount of 20-80 wt %, preferably 30-70 wt %. If the content of the powder is less than 20 wt %, the final resin composition will have an unduly high surface resistance; if the powder content is more than 80 wt %, not only does the strength of the resin composition decrease but also the cost of its production will increase.
The present invention is described below in greater detail with reference to the following examples, which are given here for illustrative purposes only and are by no means intended to be limiting.
EXAMPLE 1
A hundred grams of rutile titanium dioxide (KR-310 of Titan Kogyo K.K.; specific surface area, 7 m 2 /g) was dispersed in 1 L of water to prepare an aqueous suspension, which was warmed and held at 70° C. In a separate step, a solution was prepared by dissolving 11.6 g of stannic chloride (SnCl 4 .5H 2 O) in 100 ml of 2N HCl. This solution and 12 wt % aqueous ammonia were added simultaneously to the suspension over a period of about 40 min, with care taken to maintain a pH of 7-8. In another separate step, 36.7 g of indium chloride (InCl 3 ) and 5.4 g of stannic chloride (SnCl 4 .5H 2 O) were dissolved in 450 ml of 2N HCl. This solution and 12 wt % aqueous ammonia were dripped simultaneously to the suspension over a period of about 1 h, with care taken to maintain a pH of 7-8. After the end of dripping, the treated suspension was filtered and washed. The resulting cake of the treated pigment was dried at 110° C.
Subsequently, the dried powder was heat treated in a nitrogen gas stream (1 L/min) at 500° C. for 1 h to yield the desired white conductive powder.
The powder has a volume resistivity of 3.9Ω·cm. The coating on the surfaces of the particles was very uniform as shown by a transmission electron micrograph in FIG. 1.
EXAMPLE 2
A desired white conductive powder was produced by repeating the procedure of Example 1 except that the rutile titanium dioxide was replaced by aluminum oxide (AKP-30 of Sumitomo Chemical Co., Ltd.; specific surface area, 6 m 2 /g) and that the amount of stannic chloride was increased from 11.6 g to 16.2 g. The powder had a volume resistivity of 8.2Ω·cm.
EXAMPLE 3
A desired white conductive powder was produced by repeating the procedure of Example 1 except on the following points: the rutile titanium dioxide was replaced by zinc oxide (zinc white of Mitsui Mining & Smelting Co., Ltd.); the amount of stannic chloride was increased from 11.6 g to 16.2 g, and the amounts of indium chloride and stannic chloride were increased from 36.7 g and 5.4 g to 51.3 g and 13.3 g. respectively. The powder had a volume resistivity of 39Ω·cm.
EXAMPLE 4
A desired white conductive powder was produced by repeating the procedure of Example 1 except that the rutile titanium dioxide was replaced by barium sulfate (B-50 of Sakai Chemical Industry Co., Ltd.) and that the amounts of lndium chloride and stannic chloride were reduced from 36.7 g and 5.4 g to 23.2 g and 4.7 g, respectively. The powder had a volume resistivity of 47Ω·cm.
EXAMPLE 5
A desired white conductive powder was produced by repeating the procedure of Example 1 except for the following: the rutile titanium dioxide was replaced by potassium titanate (HT-300 of Titan Kogyo K.K.; specific surface area, 3 m 2 /g); the amount of stannic chloride was reduced from 11.6 g to 6.0 g; and the amounts of indium chloride and stannic chloride were reduced from 36.7 g and 5.4 g to 31.9 g and 4.7 g, respectively. The powder had a volume resistivity of 87Ω·cm.
EXAMPLE 6
A desired white conductive powder was produced by repeating the procedure of Example 1 except for the following: the rutile titanium dioxide was replaced by anatase ultrafine particulate titanium dioxide (STT-65C of Titan Kogyo K.K.; specific surface area, 60 m 2 /g); the solution of stannic chloride (11.6 g) in 2N HCl (100 ml) was replaced by a solution of stannic chloride (39.8 g) in 2N HCl (300 ml); and the solution of indium (36.7 g) and stannic chloride (5.4 g) in 2N HCl (450 ml) was replaced by a solution of indium chloride (159.6 g) and stannic chloride (23.5 g) in 2N HCl (1000 ml). The powder had a volume resistivity of 42Ω·cm.
EXAMPLE 7
A desired white conductive powder was produced by repeating the procedure of Example 1 except that the rutile titanium dioxide was replaced by muscovite (SUZOLITE MIKA of Kuraray Co., Ltd.; specific surface area, 7 m 2 /g). The powder had a volume resistivity of 22Ω·cm.
EXAMPLE 8
A desired white conductive powder was produced by repeating the procedure of Example 1 except for the following: the rutile titanium dioxide was replaced by zirconium oxide (high-strength zirconia of Tosoh Corp.; specific surface area, 17 m 2 /g); the amount of stannic chloride was increased from 11.6 g to 23.2 g; the solution of indium chloride (36.7 g) and stannic chloride (5.4 g) in 2N HCl (450 ml) was replaced by a solution of indium chloride (73.4 g) and stannic chloride (10.8 g) in 2N HCl (900 ml). The powder had a volume resistivity of 32Ω·cm.
COMPARATIVE EXAMPLE 1
A comparative sample of white conductive powder was produced by repeating the procedure of Example 1 except that no treatment was conducted using the solution of stannic chloride (11.6 g) in 2N HCl (100 ml). The sample powder had a very high volume resistivity (3.9×10 5 Ω·cm) and the coverage of the particles was such that the coating separated from the substrate in many areas as shown by a transmission electron micrograph in FIG. 2.
COMPARATIVE EXAMPLE 2
Another comparative sample of white conductive powder was produced by repeating the procedure of Example 1 except that the heat treatment was conducted in air rather than in a nitrogen gas stream. The sample powder also has a very high volume resistivity (4.3×10 3 Ω·cm).
EXAMPLE 9
The white conductive powder produced in Example 1 was kneaded with a high-density polyethylene (SHOREX SS55008 of Showa Denko K.K.) using a twin-roller mill (Kansai Roll K.K.) at 170° C. for 2 min, yielding white conductive resin compositions. The compositions were shaped into sheets about 0.6 mm thick by means of a pressure molding machine heated at 180° C. The sheets were subjected to the measurement of various characteristics. In the preparation of the test sheets, the concentration of the white conductive powder was varied at 30 wt %, 50 wt % and 70 wt % by adjusting the relative proportions of the powder and the polyethylene resin at 30/70, 50/50 and 70/30 in grams.
The results of measurements are shown in Tables 1 and 2; Table 1 lists the colorimetric values and volume resistivities of the conductive resin compositions, and Table 2 lists the degree of color change or discoloration that occurred under light. The test specimens had high degrees of whiteness (L values) but experienced less discoloration (ΔE) under light, thus providing to be light-fast. It also had good conduction properties as evidenced by low volume resistivities.
Various physical properties were measured by the following methods.
(Colorimetry on resin sheets)
The resin sheets were subjected to colorimetry with a color tester (SC-2-CH of Suga Test Instruments Co., Ltd.)
(Discoloration under light)
A resin sheet was placed on top of the sample holder of the color tester and exposed to light from a light source for 10 min. Colorimetry was then conducted on the exposed sample and the measured values were subtracted from the initial (t=0 min) values (L, a, b). The differences ΔL, Δa, Δb and ΔE were used as indices of discoloration.
(Volume resistivity)
Each resin sheet was cut into square (1 cm×1 cm) strips, which were coated with conductive silver paste on both top and bottom surfaces and dried for 24 h. The electric resistance of each strip was measured with an LCR meter (model 4261A) or a high-resist meter (both by Yokogawa Hewlett-Packard, Ltd.) and the volume resistivity was calculated by the formula set forth below. The thickness of the resin sheet was measured exactly with an electronic micrometer (MH-100 of Shinko Denshi Co., Ltd.) ##EQU1##
COMPARATIVE EXAMPLE 3
Specimens of comparative white conductive resin composition were produced by repeating the procedure of Example 9 except that a commercial grade of white conductive titanium dioxide that was coated with antimony-doped tin dioxide (CTR-72 of Titan Kogyo K.K.; volume resistivity, 2.8Ω·cm) was used as the white conductive powder.
The results of measurements on the specimens are shown in Tables 1 and 2; Table 1 lists the colorimetric values and volume resistivities of the specimens, and Table 2 lists the degree of discoloration that occurred under light. The comparative specimens had satisfactorily low volume resistivities; however, compared to the sample of Example 9, they had low degrees of whiteness (L values) and experienced great discoloration (ΔE) under light; in particular, the drop in whiteness (ΔL) was substantial enough to produce a blue black spot in areas exposed to light.
COMPARATIVE EXAMPLE 4
Specimens of another comparative white conductive resin composition were produced by repeating the procedure of Example 9 except that aluminum-doped zinc oxide (conductive zinc oxide 23K of Hakusui Chemical Industry Co., Ltd.; volume resistivity, 187Ω·cm) was used as the white conductive powder.
The results of measurements on the specimens are shown in Tables 1 and 2; Table 1 lists the colorimetric values and volume resistivities of the specimens, and Table 2 lists the degree of discoloration that occurred under light. The discoloration that occurred in the specimens under light was very small, demonstrating their satisfactory light fastness. On the other hand, the degrees of whiteness (L values) were low and the volume resistivities were about two orders of magnitude high compared to the sample of Example 9.
TABLE 1__________________________________________________________________________ Pigment concentrationPowder's 30 wt % 50 wt % 70 wt % volume resistivity volume resistivity volume resistivity volume resistivityRun (Ω · cm) L value (Ω · cm) L value (Ω · cm) L value (Ω · cm)__________________________________________________________________________Example 9 3.9 91.5 7.9 × 10.sup.8 90.8 5.8 × 10.sup.5 90.2 9.0 × 10.sup.3Comparative 2.8 81.1 7.7 × 10.sup.8 79.0 5.0 × 10.sup.5 77.4 8.6 × 10.sup.3Example 3Comparative 187 84.4 .sup. 5.6 × 10.sup.10 83.7 2.8 × 10.sup.7 82.3 1.0 × 10.sup.6Example 4__________________________________________________________________________
TABLE 2______________________________________ Light-induced discoloration in conductive resin composition containing 50 wt % pigmentRun ΔL Δa Δb ΔE______________________________________Example 9 -0.16 -0.14 -0.26 0.34Comparative -1.08 -0.26 -0.35 1.16Example 3Comparative -0.07 0.00 -0.32 0.33Example 4______________________________________ | The improved white conductive powder comprises white inorganic pigment particles the surfaces of which are coated with an electrically conductive layer of a dual structure consisting of a lower tin dioxide sub-layer and an upper tin dioxide-containing indium oxide sub-layer. To produce the powder, the hydration product of tin is deposited uniformly on the surfaces of white inorganic particles and, subsequently, an overcoat of indium oxide hydrate containing 0.1-20 wt % of tin dioxide is formed, followed by a heat treatment that is conducted at 350°-750° C. in a non-oxidizing atmosphere.
A resin composition containing this powder retains both the good conduction properties of a white conductive resin composition incorporating a conductive powder the particles of which are coated with antimony-doped tin dioxide and the high photostability of a white conductive resin composition incorporating an aluminum-doped conductive zinc oxide powder and yet the composition has a much higher degree of whiteness than either prior art resin composition. | 8 |
CROSS-REFERENCE TO RELATED APPLICATIONS
This application is a Continuation application of prior U.S. patent application Ser. No. 14/280,367 filed May 16, 2014, which is a Continuation application of prior U.S. patent application Ser. No. 13/923,865 filed Jun. 21, 2013 (now U.S. Pat. No. 8,776,618), which is a Continuation application of prior U.S. patent application Ser. No. 13/455,591 filed Apr. 25, 2012 (now U.S. Pat. No. 8,584,532), which claims priority under 35 U.S.C. §119 to Korean Application No. 10-2011-0038654 filed on Apr. 25, 2011, whose entire disclosures are hereby incorporated by reference.
BACKGROUND
1. Field
The present invention relates generally to a rotor for a torque sensor and, more particularly, to a rotor for a torque sensor, configured to improve a mechanical coupling force with respect to a jig in a process of adjusting a torque center, thus enabling a fine adjustment.
2. Background
Generally, a vehicle is configured to change a driving direction by manipulating a steering wheel connected to a wheel. However, if resistance between the wheel and a road is large or there is an obstacle to steering, a manipulation force is decreased, thus making it difficult to rapidly manipulate. In order to solve the problem, a power steering system has been used. Such a power steering system includes a power unit to manipulate the steering wheel, thus reducing a manipulation force.
In order for the power unit to assist in manipulating the steering wheel, it is necessary to measure torque acting on a steering shaft. Thus, several types of devices are used to measure torque of the steering wheel. Among them, a device detecting torque by measuring a magnetic field relative to a magnet coupled to the steering shaft has been widely used because it is more economical.
A general steering structure includes an input shaft to which a steering wheel is coupled, an output shaft coupled to a pinion engaging with a rack bar of a wheel, and a torsion bar connecting the input shaft and the output shaft.
If the steering wheel rotates, a rotating force is transmitted to the output shaft, and the wheel changes its direction by interaction between the pinion and the rack bar. Here, the larger resistance is, the more the input shaft rotates. Hence, the torsion bar is twisted. A degree to which the torsion bar is twisted is measured by the torque sensor using the magnetic field.
When the steering wheel is not manipulated, the torque sensor maintains a central position. If a set center is erroneous, there occurs a difference in auxiliary steering force between left and right sides during a manipulation of the steering wheel. Thus, as for the power steering system, it is very important to adjust the center of the torque sensor.
FIG. 1 is a perspective view showing a conventional rotor for a torque sensor.
A rotor 1 having a magnet 2 is coupled to an input shaft of a steering system, and a stator (not shown) is coupled to an output shaft.
If the torsion bar is twisted by a difference in rotation amount between the input shaft coupled to the rotor 1 and the output shaft coupled to the stator, the magnet 2 and the stator rotate relative to each other. At this time, opposite surfaces between the magnet 2 and the stator are changed, so that a magnetization value is changed, and thereby torque may be measured using the change in magnetization value.
The rotor 1 includes a sleeve 4 coupled to an outer circumference of the input shaft, and a yoke 3 coupled with the sleeve 4 to allow the magnet 2 to be coupled to an outer circumference thereof.
In order to adjust the center of the torque sensor, there has been used a method of holding a predetermined portion on the outer circumference of the sleeve 4 by a jig and then rotating the rotor 1 by a frictional force.
However, such a method is problematic in that the jig rotates the outer circumference of the sleeve by the frictional force, so that there is a relatively strong possibility that the jig will slip from the sleeve, and it is difficult to finely adjust the center.
The above references are incorporated by reference herein where appropriate for appropriate teachings of additional or alternative details, features and/or technical background.
SUMMARY
Accordingly, the present invention has been made keeping in mind the above problems occurring in the prior art, and an object of the present invention is to provide a rotor for a torque sensor, capable of more precisely performing a center adjusting operation.
According to one aspect of this invention, there is provided a rotor for a torque sensor, the rotor comprising: a rotor body including a sleeve coupled to a rotating shaft, and a yoke protruding from an outer circumference of the sleeve; a ring-shaped magnet coupled to an outer circumference of the yoke; and an anti-slip structure formed on the rotor body and partially coming into contact with a jig during a rotating process for adjusting a torque center, thus inhibiting slipping between the rotor body and the jig when a rotating force is transmitted. Thus, slipping between the jig and the rotor body is inhibited to enable precise transmission of the rotating force, so that accuracy is improved during fine adjustment of the torque center.
Further, the anti-slip structure may include a serration formed on an upper end of the yoke in a circumferential direction thereof, the serration coming into contact with a lower end of the jig during the rotating process for adjusting the center, thus transmitting the rotating force from the jig to the yoke. Thus, the jig is brought into contact with the yoke, thus allowing the rotating force to be reliably transmitted when the center is adjusted.
Further, the anti-slip structure may include a hole formed in the outer circumference of the sleeve, and a protrusion formed on the jig is inserted into the hole, thus transmitting the rotating force from the jig to the sleeve. Thus, the jig comes into contact with the sleeve, thus allowing the rotating force to be more reliably transmitted when the center is adjusted.
Further, the anti-slip structure may include a knurled portion formed on the outer circumference of the sleeve, and the jig partially comes into contact with the knurled portion of the sleeve, thus transmitting the rotating force from the jig to the sleeve. Thus, a frictional force between the sleeve and the jig is improved, thus allowing the rotating force to be reliably transmitted.
Further, the anti-slip structure may include a depression formed downwards from an upper end of the sleeve, and a protrusion formed on the jig is inserted into the depression, thus transmitting the rotating force from the jig to the sleeve. Thus, a mechanical coupling force between the sleeve and the jig is excellent.
Meanwhile, according to another aspect of this invention, there is provided a rotor for a torque sensor, the rotor comprising: a rotor body coupled to a rotating shaft; a ring-shaped magnet disposed to protrude to an outer circumference of the rotor body; and an anti-slip structure formed on the rotor body, wherein during a rotating process for adjusting a torque center, a jig comes into contact with the outer circumference of the rotor body or an upper portion of the magnet, and the anti-slip structure is formed on a surface making contact with the jig, thus inhibiting slipping between the jig and the rotor body. Thus, a frictional force between contact portions of the jig and the rotor is improved, so that the accuracy of a center adjustment is improved.
A rotor for a torque sensor according to the present invention constructed as described above is advantageous in that a frictional force is increased at a portion coupled with a jig when a center of the rotor is adjusted, thus providing various structures that enable precise transmission of a rotating force, and thereby permitting a fine adjustment of the torque center, therefore improving operational reliability of a steering system.
BRIEF DESCRIPTION OF THE DRAWINGS
The embodiments will be described in detail with reference to the following drawings in which like reference numerals refer to like elements wherein:
FIG. 1 is a perspective view showing a conventional rotor for a torque sensor;
FIG. 2 is a perspective view showing a rotor for a torque sensor according to the present invention;
FIG. 3 is a perspective view showing a coupling of a jig and a rotor for a torque sensor according to an embodiment of the present invention; and
FIG. 4 is a perspective view showing a coupling of a jig and a rotor for a torque sensor according to another embodiment of the present invention.
DETAILED DESCRIPTION
Hereinafter, a rotor for a torque sensor according to the preferred embodiment of the present invention will be described in detail with reference to the accompanying drawings.
FIG. 2 is a perspective view showing a rotor for a torque sensor according to the present invention.
A magnet 20 is shaped like a ring, and is generally coupled to an outer circumference of an input shaft of a steering system to be rotated along with the input shaft.
Further, a stator (not shown) is connected to an output shaft to be rotated along with the output shaft.
It can be understood that torsion occurs when there is a difference in rotation amount between the input shaft and the output shaft due to resistance of a wheel. The difference is measured using a magnetic field as described above. Of course, the magnet 20 may be connected to the output shaft, and the stator may be connected to the input shaft.
The rotor 10 includes a rotor body and the ring-shaped magnet 20 . The rotor body includes a ring-shaped yoke 30 that protrudes outwards from a lower end of a sleeve 40 taking a shape of a hollow cylinder. The magnet 20 is coupled to an outer circumference of the rotor body. To be more specific, the magnet 20 is coupled to an outer circumference of the yoke 30 .
As described above, an inner circumference of the sleeve 40 is connected to a rotating shaft of the steering system to be rotated along with the rotating shaft.
Further, the yoke 30 is coupled to the sleeve 40 to support the magnet 20 and thereby rotate along with the sleeve 40 . However, the yoke 30 may be integrated with the sleeve 40 .
Preferably, the magnet 20 comprises two or more magnet segments that are to be connected to each other. To be more specific, a plurality of arc-shaped magnet segments forms the ring-shaped magnet 20 .
The rotor 10 is coupled to the rotating shaft of the steering system by fitting the rotor 10 over the rotating shaft starting from a lower portion of the sleeve 40 , and a torque center is adjusted by an additional device, a jig.
According to the present invention, the rotor body has a shape to allow rotating power to be reliably transmitted between the jig and the rotor 10 , thus inhibiting slipping between the rotor body and the jig when the torque center is adjusted, and thereby enabling a precise adjustment. Such a shape may be implemented by various embodiments of anti-slip structures, for example, a structure for increasing a frictional force between contact portions, such as a serration or a micro groove, or a structure for providing a mechanical coupling force, such as a hole or a recess.
Thus, as a first embodiment for increasing a rotating frictional force, a serrated portion 31 is formed on an upper end of the yoke 30 .
The serrated portion 31 is circumferentially formed on an upper surface of the yoke 30 protruding outwards from a lower end of the sleeve 40 , thus having an uneven shape. It is preferable that the uneven shape be a wedge shape to allow the serrated portion 31 to be easily coupled to the jig.
In this case, a lower end of the jig is brought into contact with an upper end of the uneven serrated portion 31 to transmit a rotating force.
Further, as a second embodiment for increasing a frictional force, an uneven portion may be formed on the upper surface of the yoke 30 .
The uneven portion may be formed by fine line-shaped grooves, or may comprise a single protrusion or a plurality of protrusions. In an example of FIG. 4 , the uneven portion is formed by a plurality of diagonal line-shaped grooves.
Similarly to the first embodiment, the second embodiment provides a frictional force when a lower end of a jig comes into contact with the upper surface of the yoke 30 .
Further, as a third embodiment for increasing a frictional force, a hole 42 is formed in a side surface of the sleeve 40 .
Preferably, the hole 42 is formed in the side surface of the sleeve 40 making contact with the jig, and a protrusion is formed on a portion of the jig to be fixedly inserted into the hole 42 .
According to a shape of the jig, a single hole or a plurality of holes may be formed in the side surface of the sleeve 40 .
Meanwhile, the hole 42 may be replaced by a recess, a fine line-shaped groove, a single protrusion or a plurality of protrusions.
Further, as a fourth embodiment for increasing a frictional force, a depression may be formed in an upper end of the sleeve 40 .
The depression is depressed downwards from the upper end of the sleeve 40 . In this case, the jig comes into contact with the upper end of the sleeve 40 and includes a protrusion that may be inserted into the depression, thus maximizing a frictional force therebetween.
The above embodiments for increasing the frictional force may be selectively applied, but two or more embodiments may combine with each other.
For example, both the serrated portion 31 of the yoke 30 and the hole 42 of the sleeve 40 may be formed, and the jig may be disposed to be in contact with both the upper surface of the yoke 30 and the side surface of the sleeve 40 . In this case, since a frictional force between contact surfaces of the rotor 10 and the jig is maximized, a center adjusting operation can be precisely performed.
FIG. 3 is a perspective view showing a coupling of a jig and a rotor for a torque sensor according to an embodiment of the present invention.
While the torque center of the rotor for the torque sensor is adjusted, the lower end of the jig 50 comes into contact with the upper surface of the yoke 30 in a state in which the rotor 10 is coupled to an outer circumference of the rotating shaft.
Since the serrated portion 31 is formed on the upper surface of the yoke 30 and a serrated portion is also formed on the lower end of the jig 50 to correspond to a shape of the serrated portion 31 , a rotating force can be precisely transmitted between the yoke 30 and the jig 50 .
FIG. 4 is a perspective view showing a coupling of a jig and a rotor for a torque sensor according to another embodiment of the present invention.
Unlike the embodiment of FIG. 3 , a jig 51 comes into contact with the side surface of the sleeve 40 .
A diagonal line-shaped knurled portion 43 is formed on the side surface of the sleeve 40 . The knurled portion 43 increases a frictional force at a contact portion between the sleeve 40 and the jig 51 , thus allowing a rotating force to be precisely transmitted.
Of course, as described above, the knurled portion 43 may be replaced by a hole 42 or a protrusion.
According to the above embodiment, the jig comprises two long bars. However, the jig may be selected from various shapes including one bar and a ring, as long as it may transmit a rotating force to the rotor and adjusts the center.
The present invention provides various structures for precisely transmitting a rotating force by increasing a frictional force at a portion coupled with a jig when a center of a rotor of a torque sensor is adjusted. Thus, a fine adjustment of the torque center is possible. This improves operational reliability of a steering system.
The present invention has been described with reference to embodiments and the accompanying drawings. However, it is to be understood that the scope of the invention is not limited by the specific embodiments and drawings except as defined in the appended claims.
Any reference in this specification to “one embodiment,” “an embodiment,” “example embodiment,” etc., means that a particular feature, structure, or characteristic described in connection with the embodiment is included in at least one embodiment of the invention. The appearances of such phrases in various places in the specification are not necessarily all referring to the same embodiment. Further, when a particular feature, structure, or characteristic is described in connection with any embodiment, it is submitted that it is within the purview of one skilled in the art to effect such feature, structure, or characteristic in connection with other ones of the embodiments.
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. | Disclosed is a rotor for a torque sensor configured to improve a mechanical coupling force with respect to a jig in a process of adjusting a torque center, thus enabling a fine adjustment, the rotor including a rotor body having a sleeve coupled to a rotating shaft and a yoke protruding from an outer circumference of the sleeve, a ring-shaped magnet coupled to an outer circumference of the yoke, and an anti-slip structure formed on the rotor body and partially coming into contact with a jig during a rotating process for adjusting a torque center, thus inhibiting slipping between the rotor body and the jig when a rotating force is transmitted, so that slipping between the jig and the rotor body is inhibited to enable precise transmission of the rotating force whereby accuracy is improved during fine adjustment of the torque center. | 6 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates generally to rolling shutters for building openings, and more particularly to means for securing the shutters closed.
2. Description of the Prior Art
Rolling shutters have been known for many years. The need for locking such shutters in the closed condition has long been recognized. Devices for this purpose include bolt action bars in the bottom slat, pin locks manually inserted through a wall into a hole in the bottom slat, hinge locks, pin locks disposed between slats, sliding latches, or an offset slat. One or more of these approaches is shown in some of the following United States and foreign patents noted in the course of a preliminary search:
United States PatentsPat. No. Inventor Issue Date______________________________________2,019,084 Miller Oct. 29, 19352,921,628 Alvarez Jan. 19, 19603,302,692 Grau Feb. 7, 19673,819,217 Savino June 25, 1974______________________________________
German PatentsPat. No. Inventor Issue Date______________________________________ 134,505 Kimmich Sept, 20, 1902 354,717 Markgraf June 14, 19221,938,390 Kuhn Feb. 11, 1971______________________________________
Some of the shortcomings of the prior art locks include, for the bolt action locks, access from the inside, difficulty or impossibility of use where window screens are employed, and inability to use them where fixed windows are employed. As to the pin locks, the pins are typically loose, small, and are susceptible to bending and/or loss.
There has remained a need for a simple, reliable, inexpensive means for locking rolling shutters, and which is independent of the presence or absence of window screens, and whether or not the opening has a fixed or movable window therein, and which is as readily useful for door openings as for window openings. The present invention is directed toward meeting the need.
SUMMARY OF THE INVENTION
Described briefly in a typical embodiment of the present invention, a rolling shutter assembly is provided with the normal shutter slats, and additional lock slats, the latter being disposed adjacent the shutter storing roller and serving to connect the shutter slats to the roller. The locking slat guide means are provided to prevent an external force applied to the shutter slats (as by an intruder prying upwardly) when the shutter is closed, from bunching up or disarranging the locking slats, and they thereby preclude the displacement of the shutter slats from their correct disposition covering the opening.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a section through a building wall at an opening therein having a shutter assembly incorporating a typical embodiment of the present invention, a portion of the shutter and wall being omitted to conserve space in the drawings.
FIG. 2 is a front elevational view of the shutter assembly itself, looking in the direction of arrow 2 in FIG. 1, a portion of the shutter assembly being omitted to conserve space in the drawing.
FIG. 3 is a fragmentary sectional view similar to FIG. 1 but showing the invention applied to a strap operated shutter assembly.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring now to the drawings in detail, FIG. 1 is a section through the wall of a building at an opening therein, the type of wall being the well-known wood frame construction with wood shingle or clapboard siding. The framing studs are at 11, the sill plate 12, the window sill 13, the exterior siding at 14, and the interior wallboard at 16. The illustrated window is of the double-hung type, the upper pane thereof being shown at 17 and the lower pane at 18, the remainder of the windows being omitted from the drawing to conserve space. Although a screen is not shown in the opening, there is a space for a screen at 19, below the window frame header 21.
The shutter assembly includes the shutter slats 22 shown deployed in front of the window in the shutter-closed condition. The opposite ends of each slat are received, guided, and retained in the side guide rails 23 at the sides of the window and secured to the window frame.
For storage of the shutter slats in the shutter-open condition, a storage roller shown in the form of an octagonal drum 26, is mounted above the opening and to the exterior of the building, by means of an idler bracket assembly 28 and a crank bracket assembly 29, both of which are affixed to the exterior wall of the building and provide bearing support for the opposite ends of the roller. In the illustrated embodiment, the roller can be rolled clockwise (FIG. 1) to deploy the shutters in front of the opening, or counterclockwise to roll all of the shutters onto the roller so that the bottom slat 22B is then immediately adjacent the window frame header 21, for example. To drive the roller in the clockwise and counterclockwise direction, there is a gear 27 secured to the roller, and a pinion or worm 28 engaging the gear, the worm being mounted on a shaft 29 which extends through the wall and may be supported at the inside face of the wall in a bearing bracket 31, for example.
A crank handle 32, link 33, and shaft 34 inside the building are connected through universal joint 36 to the shaft 29. Therefore, the shaft 29 can be cranked in either rotational direction by means of the handle 32, to raise or close the shutter. When the handcrank is not being used for operation of the shutter, it can be permitted to hang at the inside of the window in the position shown by the dotted line 34A and retained in that position by a spring clip 36, for example, secured to the inside of the window frame. It will be readily recognized that instead of a handcrank, an electric motor could be connected to the shaft 29, preferably outside the building and inside the housing 37 for the rolling shutter, and operated by a reversible switch at the inside of the building. The drive for the roller can be accomplished otherwise by using an electric motor at another location, or inside the roller itself, or by using an operating strap or other means. For purposes of the present example, the drive ratio between the roller itself and the shaft driving it should be 1:5, 1:8, 1:10 or higher. That is, the number of turns of the roller per turn of the motor or crankshaft or other means driving it, should be comparatively small so that the roller cannot be turned by external force applied thereto. Of course, it is clear that when the handcrank is hanging vertically adjacent the wall on the interior of the building, and particularly if it is clipped in position, the shutter storage roller cannot be turned by an external force, without breaking something. It is intended further that the structure be of sufficient strength that it will not be broken by any external force which could be applied to the roller by pushing upward on the shutters in such manner as would tend to roll them onto the roller.
To utilize the slat storage roller according to a typical embodiment of the present invention, locking slats are employed at 38, 39, 40 and 41. These locking slats are virtually the same as slats 22 except that, as seen in FIG. 2, they are somewhat longer, the ends of shutter slats being designated at 22E, for example, and the ends of locking slats at 38E, for example. Therefore, the end portions of the locking slats are in facing relationship to security blocks 42 affixed to the building wall according to the invention, immediately inboard of the brackets 28 and 29. Yet it will also be noted that these blocks are outboard of the ends of the slats 22. FIG. 1 shows that the block 42 has a curved slat-guiding and confining face 43 which curves upward from a point 44 immediately above the shutter slat guide rails 23, but outboard thereof, to a point 46 above and adjacent the roller 26. This surface contacts the faces of the end portions of slats 38, 39 and 40, and is very close to the end portions of slat 41. It will prevent any disarrangement or bunching upward of the slats 38, 39, 40 and 41, which might otherwise occur if an upward force were applied against them in the direction of arrow 48 as would occur, for example, if a prospective intruder inserted a wrecking bar 49 between the window sill and the bottom slat 22B of the rolling shutter in an effort to gain entry to the building through the window. Therefore, since the usual conventional construction of the shutter slats themselves and connection of one to another will prevent them from separating from each other, either when they are pulled apart or pushed together, the present invention will preclude the forcing open or upward of the shutter slats and yet not interfere with the normal rolling up thereof onto the roller 26 when it is driven by the crank, by the motor, or by the designated appropriate means. This is because the shutter slats 22 can roll up between the security blocks 42 without contact therewith, just as shutter slats normally roll onto the roller. Therefore, although conventionally the upper shutter slat 22A might be connected to the roller by a string, band, or other means which, upon rolling the roller, would pull the shutters onto the roller, according to the present invention additional slats (the lock slats) are used for that purpose and serve the additional purpose of locking the shutter in the closed position when the roller is secured from rotation.
In order to prevent the lock slats from descending or falling too far away from the guide and confining surface 43, lock springs 51 are employed and extend downward from their points of attachment by screws 52 to the roller assembly, to the lower ends 53 of the springs. These springs are flexible enough to roll onto the roller as it is rolled by means of the crank or motor as the shutter is opened. However, as the shutter is closed, the spring will unwrap from the roll and maintain the unrolling locking slats 38, 39 and 40 in constant sliding engagement with the surface 43 of each of the security blocks.
As shown in FIG. 3, the present invention is applicable also where the shutter is strap-operated. In that case, the locking slats and guides are the same as in the previous embodiment. However, the operating strap 56 extending from the strap reel 57 to the recoil reel 58 is used to open and close the shutter in conventional manner. The recoil spring in box 59 urges the recoil reel in the clockwise direction of arrow 61 with a force of about six or seven pounds. This is desirable particularly when the shutter is closed (most of strap wound on strap reel 57 and unwound from recoil reel 58) to aid the user in raising the shutter. The tongue 62 (shown much enlarged) pivoting on the recoil box about hinge pin 63, is capable of pinching the strap against bar 64 at 65 when the strap portion extending up to pulley 66 contacts the tongue at 67 and pushes it in the direction of arrow 68 toward the end of the recoil box. This is useful to hold the shutter in any desired partially open position, as it prevents the strap from being pulled out of the recoil box by the weight of the shutter tending to unroll more shutter from roller 26.
By providing a small clamp 69 to lock the tongue in the up (strap clamping) condition when the shutter is closed, the recoil spring cannot move the strap which is clamped against bar 64, so is unable to tend to roll up the shutter. Therefore, a would-be intruder is unable to jiggle the shutter upward, as he might otherwise be able to do if the six or seven pound pull were being exerted on the strap reel 57 by the strap 56.
It will be seen and recognized from the foregoing description that the present invention provides a convenient, inexpensive, and reliable security locking system for rolling shutters whether they be for window openings or door openings in a building. | A rolling shutter for building wall openings, has extra-long locking slats connecting the usual shutter slats to the slat storing roller. Lock slat guide blocks located adjacent the roller and outboard of the shutter slats cooperate with the lock slats when the shutter is closed to preclude disarrangement of the lock slats by a shutter opening force externally applied to the shutter slats, when the roller is locked. | 4 |
This application is a continuation-in-part of application Ser. No. 09/272,137, filed Mar. 19, 1999.
The present invention is directed to a method of making carboxylated cellulose fibers including those in which fiber strength and degree of polymerization is not significantly sacrificed. The invention is further directed to the carboxylated fibers and to products made using the fibers.
BACKGROUND OF THE INVENTION
Cellulose is a carbohydrate consisting of a long chain of glucose units, all β-linked through the 1′-4 positions. Native plant cellulose molecules may have upwards of 2200 anhydroglucose units. The number of units is normally referred to as degree of polymerization or simply D.P. Some loss of D.P. inevitably occurs during purification. A D.P. approaching 2000 is usually found only in purified cotton linters. Wood derived celluloses rarely exceed a D.P. of about 1700. The structure of cellulose can be represented as follows:
Chemical derivatives of cellulose have been commercially important for almost a century and a half Nitrocellulose plasticized with camphor was the first synthetic plastic and has been in use since 1868. A number of cellulose ether and ester derivatives are presently commercially available and find wide use in many fields of commerce. Virtually all cellulose derivatives take advantage of the reactivity of the three available hydroxyl groups. Substitution at these groups can vary from very low; e.g. about 0.01 to a maximum 3.0. Among important cellulose derivatives are cellulose acetate, used in fibers and transparent films; nitrocellulose, widely used in lacquers and gun powder; ethyl cellulose, widely used in impact resistant tool handles; methyl cellulose, hydroxyethyl, hydroxypropyl, and sodium carboxymethyl cellulose, water soluble ethers widely used in detergents, as thickeners in foodstuffs, and in papermaking.
Cellulose itself has been modified for various purposes. Cellulose fibers are naturally anionic in nature as are many papermaking additives. A cationic cellulose is described in Harding et al. U.S. Pat. No. 4,505,775. This has greater affinity for anionic papermaking additives such as fillers and pigments and is particularly receptive to acid and anionic dyes. Jewell et al., in U.S. Pat. No. 5,667,637, teach a low degree of substitution (D.S.) carboxyethyl cellulose which, along with a cationic resin, improves the wet to dry tensile and burst ratios when used as a papermaking additive. Westland, in U.S. Pat. No. 5,755,828 describes a method for increasing the strength of articles made from crosslinked cellulose fibers having free carboxylic acid groups obtained by covalently coupling a polycarboxylic acid to the fibers.
For some purposes cellulose has been oxidized to make it more anionic; e.g., to improve compatibility with cationic papermaking additives and dyes. Various oxidation treatments have been used. Among these are nitrogen dioxide and periodate oxidation coupled with resin treatment of cotton fabrics for improvement in crease recovery as suggested by R. T. Shet and A. M. Yabani, Textile Research Journal November 1981: 740-744. Earlier work by K. V. Datye and G. M. Nabar, Textile Research Journal , July 1963: 500-510, describes oxidation by metaperiodates and dichromic acid followed by treatment with chlorous acid for 72 hours or 0.05 M sodium borohydride for 24 hours. Copper number was greatly reduced by borohydride treatment and less so by chlorous acid. Carboxyl content was slightly reduced by borohydride and significantly increased by chlorous acid. The products were subsequently reacted with formaldehyde. P. Luner et al., Tappi 50(3): 117-120 (1967) oxidized southern pine kraft springwood and summer wood fibers with potassium dichromate in oxalic acid. Handsheets made with the fibers showed improved wet strength believed due to aldehyde groups. P. Luner et al., in Tappi 50(5): 227-230 (1967) expanded this earlier work and further oxidized some of the pulps with chlorite or reduced them with sodium borohydride. Handsheets from the pulps treated with the reducing agent showed improved sheet properties over those not so treated. R. A. Young, Wood and Fiber , 10(2): 112-119 (1978) describes oxidation primarily by dichromate in oxalic acid to introduce aldehyde groups in sulfite pulps for wet strength improvement in papers. V. A. Shenai and A. S. Narkhede, Textile Dyer and Printer May 20, 1987: 17-22 describe the accelerated reaction of hypochlorite oxidation of cotton yarns in the presence of physically deposited cobalt sulfide. The authors note that partial oxidation has been studied for the past hundred years in conjunction with efforts to prevent degradation during bleaching. They also discuss in some detail the use of 0.1 M sodium borohydride as a reducing agent following oxidation. The treatment was described as a useful method of characterizing the types of reducing groups as well as acidic groups formed during oxidation. The borohydride treatment noticeably reduced copper number of the oxidized cellulose. Copper number gives an estimate of the reducing groups such as aldehydes present on the cellulose. Borohydride treatment also reduced alkali solubility of the oxidized product but this may have been related to an approximate 40% reduction in carboxyl content of the samples. R. Andersson et al. in Carbohydrate Research 206: 340-346 (1990) teach oxidation of cellulose with sodium nitrite in orthophosphoric acid and describe nuclear magnetic resonance elucidation of the reaction products.
N. J. Davis and S. L. Flitsch, Tetrahedron Letters 34(7): 1181-1184 (1993) describe the use and reaction mechanism of 2,2,6,6-tetramethylpiperidinyloxy free radical (TEMPO) with sodium hypochlorite to achieve selective oxidation of primary hydroxyl groups of monosaccharides. Following the Davis et al. paper this route to carboxylation then began to be more widely explored. A. E. J. de Nooy et al., in a short paper in Receuil des Travaux Chimiques des Pays-Bas 113: 165-166 (1994), report similar results using TEMPO and hypobromite for oxidation of primary alcohol groups in potato starch and inulin. The following year, these same authors in Carbohydrate Research 269: 89-98 (1995) report highly selective oxidation of primary alcohol groups in water soluble glucans using TEMPO and a hypochlorite/ bromide oxidant.
PCT published patent application WO 95/07303 (Besemer et al.) describes a method of oxidizing water soluble carbohydrates having a primary alcohol group, using TEMPO with sodium hypochlorite and sodium bromide. Cellulose is mentioned in passing in the background although the examples are principally limited to starches. The method is said to selectively oxidize the primary alcohol at C-6 to carboxyl. None of the products studied were fibrous in nature.
PCT application WO 99/23117 (Viikari et al.) teaches oxidation using TEMPO in combination with the enzyme laccase or other enzymes along with air or oxygen as the effective oxidizing agents of cellulose fibers, including kraft pine pulps.
A year following the above noted Besemer publication, the same authors, in Cellulose Derivatives , T. J. Heinze and W. G. Glasser, eds., Ch. 5, pp 73-82 (1996), describe methods for selective oxidation of cellulose to 2,3-dicarboxy cellulose and 6-carboxy cellulose using various oxidants. Among the oxidants used were a periodate/chlorite/hydrogen peroxide system, oxidation in phosphoric acid with sodium nitrate/nitrite, and with TEMPO and a hypochlorite/bromide primary oxidant. Results with the TEMPO system were poorly reproduced and equivocal. The statement that “. . . some of the material remains undissolved” was puzzling. In the case of TEMPO oxidation of cellulose, little or none would have been expected to go into solution. The homogeneous solution of cellulose in phosphoric acid used for the sodium nitrate/sodium nitrite oxidation was later treated with sodium borohydride to remove any carbonyl function present.
P.-S. Chang and J. F. Robyt, Journal of Carbohydrate Chemistry 15(7): 819-830 (1996), describe oxidation of ten polysaccharides including α-cellulose at 0° C. and 25° C. using TEMPO with sodium hypochlorite and sodium bromide. Ethanol addition was used to quench the oxidation reaction. The resulting oxidized a-cellulose had a water solubility of 9.4%. The authors did not further describe the nature of the α-cellulose. It is presumed to have been a so-called dissolving pulp or cotton linter cellulose. D. Barzyk et al., in Transactions of the 11 th Fundamental Research Symposium , Vol. 2, 893-907 (1997), note that carboxyl groups on cellulose fibers increase swelling and impact flexibility, bonded area and strength. They designed experiments to increase surface carboxylation of fibers. However, they ruled out oxidation to avoid fiber degradation and chose to form carboxymethyl cellulose in an isopropanol/methanol system.
Isogai, A. and Y. Kato, in Cellulose 5: 153-164 (1998) describe treatment of several native and mercerized celluloses with TEMPO to obtain water soluble and insoluble polyglucuronic acids. They note that the water soluble products had almost 100% carboxyl substitution at the C-6 site. They further note that oxidation proceeds heterogeneously at the more accessible regions on solid cellulose.
None of the previous workers have described a stable fibrous carboxylated cellulose that can be made in conventional papermill equipment in an aqueous system with minimum D.P. loss to yield a product with superior papermaking properties.
SUMMARY OF THE INVENTION
The present invention is directed to a fibrous carboxylated cellulose product, to the method of its manufacture, and to sheeted paper products using the carboxylated fibers. A chemically purified fibrous cellulose market pulp is the basic material for the process. This may be, but is not limited to, bleached or unbleached sulfite, kraft, or prehydrolyzed kraft hardwood or softwood pulps or mixtures of hardwood and softwood pulps. So-called high alpha cellulose or chemical pulps are not considered as raw materials included within the scope of the invention.
The suitability of lower cost market pulps is a significant advantage of the process. Market pulps are used for many products such as fine papers, diaper fluff, paper towels and tissues, etc. These pulps generally have about 86-88% α-cellulose and 12-14% hemicellulose whereas the high α-cellulose chemical or dissolving pulps have about 92-98% α-cellulose. To the present inventors knowledge the lower α-cellulose pulps or other cellulose having a high content of hemicellulose have never before been treated with TEMPO to produce a stable carboxylated fiber. By stable is meant minimum D.P. loss in alkaline environments, and very low self cross linking and color reversion. The method is particularly advantageous for treating secondary (or recycled) fibers. Bond strength of the sheeted carboxylated fibers is significantly improved over untreated recycled fiber.
The term “cellulose” when used hereafter and in the claims refers to a wood based cellulose market pulp below 90% α-cellulose, generally having about 86-88% α-cellulose and a hemicellulose content of about 12%.
The process of the invention will lead to a product having an increase in carboxyl substitution over the starting material of at least about 2 meq/100 g, preferably about 5 meq/100 g. Carboxylation occurs predominantly at the hydroxyl group on C-6 of the sugar units to yield uronic acids.
The cellulose fiber in an aqueous slurry or suspension is first oxidized by addition of a primary oxidizer consisting of 2,2,6,6-tetramethylpiperidinyl-1 -oxy free radical (TEMPO). A product closely related to TEMPO and also suitable is 2,2,2′2′,6,6,6′,6′-octamethyl-4,4′-bipiperidinyl-1,1′-dioxy di-free radical. Similarly, 2,2,5,5,-tetramethylpyrrolidinyl-1-oxy free radical is also satisfactory. It is also considered to be within the scope of the invention to form TEMPO in situ by oxidation of the hydroxylamines of any of the three named free radical products or from 2,2,6,6-tetramethylpiperidine. While the TEMPO is consumed and converted to a hydroxylamine during the oxidation reaction it is continuously regenerated by the presence of a secondary oxidant. A water soluble hypohalite compound is a preferred secondary oxidant. Since it is not irreversibly consumed in the oxidation reaction only a small amount of the TEMPO is required. During the course of the reaction it is the secondary oxidant which will be depleted. The amount of TEMPO required is in the range of about 0.005% to 1.0% based on cellulose present, preferably about 0.02-0.25%, and most preferably about 0.1-0.25% by weight. TEMPO is known to preferentially oxidize the primary hydroxyl located on C-6 of the anhydroglucose moiety of cellulose. It can be assumed that a similar oxidation will occur at primary alcohol groups on hemicellulose.
Preferably the TEMPO is first premixed with a portion of an aqueous hypohalite to form a homogeneous solution before addition to the cellulose fiber slurry. The oxidation reaction may be allowed to continue over a time period from about 1 minute to ten or more hours at temperatures from about 0° C. to 30° C. Following the oxidation reaction, if maximum D.P. stability is desired, the cellulose is washed and reslurried in water where it is subjected to the action of a stabilizing compound to convert substituent groups, such as aldehydes and ketones, to hydroxyl or carboxyl groups. Unstabilized TEMPO oxidized pulps have objectionable color reversion and will self crosslink upon drying, thereby reducing their ability to redisperse and to form strong bonds when used in sheeted products.
A preferred hypohalite is sodium hypochlorite (NaOCl). Sodium hypochlorite is inexpensive and readily available as a stable aqueous solution with about 5.25% NaOCl w/v. Admixture of NaOCl with sodium bromide (NaBr) will accelerate the oxidation reaction and the use of this combination is highly preferred. About 3 parts by weight NaBr to 4 parts of NaOCl has proved very satisfactory, although this ratio is not critical. The usage of NaOCl may be in the range of about 0.8-6.5 g/L of pulp slurry, preferably about 1.1-1.4 g/L. Usage of NaOCl based on cellulose will be within the range of about 0.5-35% by weight, preferably about 1.3-10.5% by weight. Exact usage will depend on the amount of carboxylation desired. The pH during oxidation should generally be maintained within the range of 8-11, preferably 9-10 and most preferably 9.5-9.8. The oxidation reaction will proceed at higher and lower pH values but at lower efficiencies.
A proprietary composition sold as Stabrex™, available from Nalco Chemical Co., Chicago, Ill., may be used in place of the hypochlorite oxidant. Stabrex is sold as an aqueous stabilized highly alkaline solution of a bromine-containing composition having 1-5% NaOH, a minimum pH of 13, and is a latent source of hypobromite. The composition contains a stabilizer which is believed to be a sulfonated nitrogen containing compound. The Stabrex is useful where environmental or other considerations might dictate against the use of chlorine based materials.
It will be understood that in accordance with usual reaction kinetics the oxidation will proceed at a higher rate with increased concentrations of oxidants and at higher temperatures. Reaction at lower temperatures; e.g., at 0°-10° C., is preferred from the standpoint of reducing cellulose D.P. degradation. However, the reaction may also be carried out at higher temperatures to produce products having a D.P. higher than 850.
Following oxidation, the cellulose is washed to remove any residual chemicals and may then be dried or further processed. If maximum stability and D.P. retention is desired the oxidized product is reslurried in water for treatment with a stabilizing agent. The stabilizing agent may either be a reducing agent or another oxidizing agent. A preferred reducing agent is preferably an alkali metal borohydride. Sodium borohydride (NaBH 4 ) is preferred from the standpoint of cost and availability. However, other borohydrides such as LiBH 4 , or alkali metal cyanoborohydrides such as NaBH 3 CN are also suitable. NaBH 4 may be mixed with LiCl to form a very useful reducing agent. When NaBH 4 is used for reduction, it should be present in an amount between about 0.1 and 100 g/L. A more preferred amount would be about 0.25-5 g/L and a most preferred amount from about 0.5-2.0 g/L. Based on cellulose the amount of reducing agent should be in the range of about 0.1% to 4% by weight, preferably about 1-3%. Reduction may be carried out at room or higher temperature for a time between 10 minutes and 10 hours, preferably about 30 minutes to 2 hours.
Alkali metal chlorites are preferred oxidizing agents used as stabilizers, sodium chlorite being preferred because of the cost factor. Other compounds that may serve equally well as oxidizers are permanganates, chromic acid, bromine, and silver oxide. A combination of chlorine dioxide and hydrogen peroxide is also a suitable oxidizer when used at the pH range designated for sodium chlorite. Oxidation using sodium chlorite may be carried out at a pH in the range of about 1.5-5, preferably 2-4, at temperatures between about 25°-90° C. for times from about 5 minutes to 50 hours, preferably about 10 minutes to 2 hours. One factor that favors oxidants as opposed to reducing agents is that aldehyde groups on the oxidized cellulose are converted to additional carboxyl groups, thus resulting in a more highly carboxylated product. These stabilizing oxidizers are referred to as “tertiary oxidizers” to distinguish them from the TEMPO/hypochlorite primary/secondary oxidizers. The tertiary oxidizer is used in a molar ratio of about 1.0-15 times the presumed aldehyde content of the oxidized cellulose, preferably about 5-10 times. In a more convenient way of measuring the required tertiary oxidizer needed, the preferred sodium chlorite usage should fall within about 0.001 g sodium chlorite/g of fiber to 0.2 g/g, preferably 0.01-0.09 g/g, the chlorite being calculated on a 100% active material basis.
After stabilization is completed, the cellulose is again washed and may be dried if desired. Alternatively, the carboxyl substituents may be converted to other cationic forms beside hydrogen or sodium; e.g., calcium, magnesium, or quaternary ammonium.
One particular advantage of the process is that all reactions are carried out in an aqueous medium to yield a product in which the carboxylation is primarily located on the fiber surface. This conveys highly advantageous properties for paper-making. The product of the invention will have at least about 20% of the total carboxyl content on the fiber surface. This is in comparison with about 10% as is the case with untreated fiber.
The carboxylated fiber of the invention is highly advantageous as a papermaking furnish, either by itself or in conjunction with conventional fiber. It may be used in amounts from 0.5-100% of the papermaking furnish. The carboxylated fiber is especially useful in admixture with recycled fiber to add strength. Its increased number of anionic sites should serve to ionically hold significantly larger amounts of cationic papermaking additives than untreated fiber. These additives may be wet strength resins, sizing chemical emulsions, filler and pigment retention aids, charged filler particles, dyes and the like. Carboxylated pulps do not hornify (or irreversibly collapse) as much on drying and are a superior material when recycled. They swell more on rewetting, take less energy to refine, and give higher sheet strength.
It is thus an object of the invention to provide a method of making a cellulose fiber having enhanced carboxyl content using an aqueous reaction medium.
It is also an object to provide a cellulose papermaking fiber having enhanced carboxyl content.
It is a further object to provide a cellulose fiber having an enhanced carboxyl content at the fiber surface.
It is another object to provide a carboxylated cellulose fiber that is stable against D.P. loss in alkaline environments.
It is yet an object to provide a stable cellulose fiber of enhanced carboxyl content with a D.P. of at least 850 measured as a sodium salt or 700 when measured in the free acid form.
It is still an object to provide a cellulose fiber having a high ionic attraction to cationic papermaking additives.
It is an additional object to provide cellulose pulp and paper products containing the carboxyl enhanced fiber.
These and many other objects will become readily apparent upon reading the following detailed description taken in conjunction with the drawings
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a graph plotting D.P. against carboxyl content for unreduced oxidized wood pulp.
FIG. 2 is a graph showing the effect of reduction time on D.P. for two concentrations of the reducing agent.
FIG. 3 is a graph showing cellulose D.P. plotted against oxidation time at three reaction temperatures.
FIG. 4 is a graph showing cellulose carboxyl content plotted against oxidation time at three reaction temperatures.
FIG. 5 is a graph showing surface carboxyl content of several fiber samples.
FIG. 6 is a graph plotting tensile index of hand sheets against density.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
It is believed that a TEMPO catalyzed cellulose oxidation predominantly occurs at the primary hydroxyl group on C-6 of the anhydroglucose moeity. In contrast to some of the other routes to oxidized cellulose, only very minor reaction is believed to occur at the secondary hydroxyl groups at the C-2 and C-3 locations. The mechanism to formation of a carboxyl group at the C-6 location proceeds through an intermediate aldehyde stage as follows:
The TEMPO is not irreversibly consumed in the reaction but is continuously regenerated. It is converted by the hypohalite into the nitrosonium (or oxyammonium) ion which is the actual oxidant. During oxidation the nitrosonium ion is reduced to the hydroxylamine from which TEMPO is again formed. Thus, it is the hypohalite salt which is actually consumed. TEMPO may be reclaimed or recycled from the aqueous system. The reaction is postulated to be as follows:
As was noted earlier, formation of TEMPO in situ by oxidation of the hydroxylamine or the amine is considered to be within the scope of the invention.
The resulting oxidized cellulose product will have an equilibrium mixture of carboxyl and aldehyde substitution. Aldehyde substituents on cellulose are known to cause degeneration over time and under certain environmental conditions. In addition, minor quantities of ketone carbonyls may be formed at the C-2 and C-3 positions of the anhydroglucose units and these will also lead to degradation. Marked D.P., fiber strength loss, crosslinking, and yellowing are among the problems encountered. For these reasons, we have found it very desirable to reduce aldehyde and ketone substituents to hydroxyl groups to ensure stability of the product.
EXAMPLE 1
Oxidation of Cellulose with TEMPO and Its Effect on D.P.
A general laboratory method for preparation of a TEMPO catalyzed oxidized cellulose is given as follows. A buffered solution at pH 9.7 was made by adding 5.05 g NaHCO 3 and 4.24 Na 2 CO 3 to 1.3 L of deionized water. To this was added 50 g, dry weight, of a bleached northern softwood kraft market pulp from an Alberta mill. Furnish for this pulp is believed to be a mixture of spruce with some pine and balsam fir. The pulp was dispersed with a mixer to form a slurry in the buffer. After dispersion, 700 g of ice was added to the pulp slurry. An oxidizing solution was made up by mixing 100 mg of TEMPO, 1.0 g of NaBr, and about 2 mL of a 5.25% solution of NaOCl. Mixing was continued until the resulting oily material was dissolved. This was then added to the pulp slurry with mild agitation. An additional 48 mL of the NaOCl solution was dripped into the slurry over the next 7 minutes. Reaction was continued for an additional 18 minutes and the treated pulp was filtered and washed several times with deionized water.
A number of variations were made in the above generalized method including adjusting concentrations of the reactants and reaction time and temperature in order to produce products having a range of carboxyl content. The test method used for determination of carboxyl content was TAPPI T 237. Briefly, the pulp is extracted with dilute HCl, washed, and reacted with a NaHCO 3 —NaCl solution. The supernatant liquid is titrated with 0.01N HCl to the methyl red endpoint. This test is believed to give a measure of the total carboxyl content of the fiber sample. Degree of polymerization (D.P.) was calculated from viscosity in cupriethylenediamine (cuene) solution determined by TAPPI Method T-230 The relative viscosity determined by the TAPPI method was converted to intrinsic viscosity by ASTM Method D-1795. This result was converted to D.P. by the equation
D.P.=(Intrinsic Viscosity×95)/Oven Dry fiber weight.
A generalized curve comparing D.P. with carboxyl content is shown in FIG. 1 . Reading from the curve it would appear that even a very low amount of carboxyl substitution by TEMPO catalyzed oxidation results in a significant D.P. reduction.
EXAMPLE 2
Effect of Reducing Agent in Preserving D.P. in TEMPO Oxidized Cellulose
A sample of oxidized cellulose was made exactly according to the generalized procedure described in Example 1. The resulting oxidized product was divided without drying into two equal parts. One portion of the oxidized pulp comprising 25 g fiber and 81 g water was suspended in 1 L of water containing 0.5 g NaBH 4 . The second portion was similarly slurried in 1 L water containing 1.0 g NaBH 4 . Both samples were at room temperature. Approximately 2 g portions of fiber were removed 1, 2.5, 5.3, 15, 30, 60, and 120 minutes after beginning of the reducing treatment. The samples were washed, and then dried at 105° C. The dried samples were then dissolved in cuene for D.P. determination. Results plotting time in the NaBH 4 reducing environment against measured D.P. are shown in the graph on FIG. 2 . The D.P. of the original untreated wood pulp was about 1700. It is apparent, and not surprising, that the higher concentration of NaBH 4 gives D.P protection at a faster rate. However, at two hours treatment time the ultimate D.P. difference was only about 100 between the higher and lower usages of the reducing agent.
It is evident that unstable substituent groups left on the cellulose with short reduction times are causing D.P. loss in the alkaline cuene solvent used for D.P. measurement. The measurement method appears to be producing a false reading of the actual D.P. of the sample before dissolution in cuene. Logic dictates that a cellulose with a D.P. of about 400 after 2 minutes reduction time could not increase in D.P. to about 1400 after 2 hours reduction time. Even though some of the lower D.P. values are an artifact of the measurement method, the results do give an excellent indication of the expected future stability of the carboxylated product.
EXAMPLE 3
Effect of NaBH 4 Concentration
A sample of oxidized cellulose was made precisely according to the generalized procedure described in Example 1. Two gram samples of the oxidized pulp were combined with varying amounts of NaBH 4 and made up with water to 80 grams total weight. Borohydride concentrations used were from 0.0078 g to 8.67 g, a range of over a thousand times difference. The borohydride treatment was 2 hours for each of the samples. D.P. measurements on the samples are shown in Table 1.
TABLE 1
Effect of NaBH 4 Concentration on D.P. Loss
NaBH 4 , g/L
NaBH 4 , M/L
D.P.
D.P. Loss, %
0.1
0.00264
700
59
0.5
0.0132
1350
21
1.0
0.0264
1460
14
5
0.132
1485
12
10
0.2264
1535
9.8
52.7
1.39
1550
9.1
111.2
2.94
1545
9.3
Control*
—
1700
0
*Original unoxidized pulp sample
It is apparent that under the conditions of this test there is little advantage gained in using more than about 0.04 moles/liter or (0.5 g/L) of NaBH 4 for D.P. protection. The massive amounts used for some of the later samples offered no advantage.
EXAMPLE 4
Effect of Oxidation Time and Temperature on D.P. and Carboxyl Content
Three samples were oxidized using a TEMPO catalyst similar to those described in the previous examples. However, in addition to the sample regularly prepared at 0° C., samples were also prepared at 10° and 22° C. During the reaction time 2 g samples were removed at about 3, 6, 10, 15, 20, and 26 minutes after the addition of the TEMPO/hypochlorite mixture. Because of the rapid reaction time at 22° C. a 26 minute sample was not taken. These were immediately washed in deionized water, drained and placed in a 1% NaBH 4 solution for 2 hours. After drying, D.P. and carboxyl content were determined on the samples. The results of D.P. vs oxidation time are shown in FIG. 3 . While D.P. loss was not severe in any of the samples under the conditions used, it is readily apparent that oxidation at lower temperatures is desirable for maximum retention of D.P. FIG. 4 shows a plot of carboxyl content vs reaction time. Again, not surprisingly, carboxyl content increases more rapidly at the higher reaction temperatures. All three samples asymptotically approach a maximum level of about 24 meq/100 g carboxyl, estimated to be reached at about 60 minutes reaction time.
EXAMPLE 5
Preparation of Highly Carboxylated Fibers
In the examples shown to the present time, maximum carboxyl content of the product has been about 25 meq/100 g. It is possible to prepare a fibrous product having much higher substitution; e.g., up to 150 meq/100 g. This may be done most readily by increasing the amount of hypohalite used and/or by extending the reaction time. To illustrate this, three samples were prepared according to the following procedures. For example 5A a buffer solution was prepared using 10.1 g NaHCO 3 and 8.48 g Na 2 CO 3 dissolved in 2.6 L of deionized water. In this was dispersed 100 g dry basis of northern softwood kraft pulp followed by the addition of 1.4 kg ice. The pH was about 9.7. An oxidizing mixture was prepared by first mixing 200 mg TEMPO with 2.00 g NaBr then adding ˜5 mL of a total 40 mL 5.25% NaOCl solution and mixing well until the oily material was dissolved. This was added to the buffered pulp slurry. The remaining 35 mL of NaOCl solution. was added slowly over the next 22 minutes. The slurry was then drained, washed, and redispersed in water with 2.13 g NaBH 4 to make a total weight of 1336 g. After 2 hours the pulp from the reducing treatment was again drained and washed. Total carboxyl content was measured as 11 meq/100 g.
For Example 5B, 190 mL of 5.25% NaOCl solution was used and the oxidation time was 2.8 hours. During oxidation the pH dropped from 9.7 to 9.3. After washing the pulp was again slurried in water with 3.2 g NaBH 4 to make a total slurry weight of 2000 g. After 1 hour the pulp was drained and washed. Total carboxyl content was measured as 49 meq/100 g.
For Example 5C the oxidizing mixture was made up of 427 mg TEMPO, 2.1 g NaBr and a total of 390 mL 5.25% NaOCl solution. At 2.8 hours after initiation of oxidation pH had dropped to 9.5 and 3 g Na 2 CO 3 was added. After 5 hours the temperature had risen to 8° C. and pH had dropped to 9.0. At that time 250 g of ice and 4 g Na 2 CO 3 were added. Again, at 7.5 hours after the start of oxidation an additional 4 g of Na 2 CO 3 was added. At 8.5 hours the slurry was drained and washed. The oxidized pulp was treated with NaBH 4 as in Example 5B. Total carboxyl content was 97 meq/100 g.
Water retention values are an important property of cellulose paper-making fibers. This property may be used to indicate swelling behavior, fiber flexibility, and fiber conformability during drying of a sheeted product. Higher values often indicate higher surface areas or relatively higher fiber saturation points. In general, higher water retention values will correlate with increased strength properties of sheeted products. Water retention as reported herein has been determined by TAPPI Method UM 256. Briefly, a sample of known dry weight is slurried in water, centrifuged, and reweighed. Water retention values, carboxyl content, and D.P. for the three products of the present example are reported in Table 2 following.
TABLE 2
Sample No.
Carboxyl, meq/100 g
D.P.
Water Retention Value, g/g
5A
11
1620
1.80
5B
49
1140
2.55
5C
97
860
4.21
Untreated
4
1700
1.35
The improvement in water retention values in all samples in immediately evident.
EXAMPLE 6
Determination of Fiber Surface vs Total Carboxyl
Total carboxyl content of the samples described to this point was, as noted, determined by TAPPI TM 237. Papermaking properties depend heavily on the surface characteristics and ionicity of fibers. It was therefore of interest to determine the distribution of carboxyl groups on and within the fibers. A high surface concentration would be presumed to be beneficial to papermaking properties; e.g. higher retention of cationic additives such as retention aids. The following test method is believed to be specific to readily accessible surface carboxyl groups. It is based on the method described in two papers by L. W{dot over (a)}gborg et al., Nordic Pulp and Paper Journal no. 2, 71-76 and 135-140. PolyDADMAC, (polydiallyldimethylammonium chloride) was obtained from Polymer Standards Service, Mainz, Germany. This polymer is a high charge density cationic compound and the material used has M w =330,000, M N =220,000 and charge L133. A 0.001 M stock solution was prepared. Into five beakers was placed respectively 3.7 mL, 9.2 mL, 18.4 mL, 27.6 mL and 36.8 mL of the polyDADMAC stock solution. Water was added to each to make the total volume slightly less than 50 mL. Then 250 μL of 2 M NaCl was added. Finally a weighed amount of treated pulp 0.15-0.25 g was added to each beaker. Water was then adjusted to make the total liquid volume (including any added with the pulp sample) to 50 mL. After 1-2 hr mixing the slurry was centrifuged and a portion of the supernatant liquid was titrated with 0.001M polyvinylsulfate, potassium salt (PVSK) from Nalco Chemical Company, Chicago, Ill.).
The amount of polyDADMAC adsorbed is dependent on concentration. At each concentration of polyDADMAC an indicated carboxyl content was recorded and plotted. A best fit line was drawn through the points. The essentially linear portion of the curve was projected and the y-intercept of the line was indicative of the surface carboxyl content.
Samples of TEMPO oxidized and NaBH 4 reduced northern softwood pulp were prepared according to the procedure of the previous examples. Samples having 7-9, 24, and 97 meq/100 g of carboxyl were tested. Additional tests were run on the untreated pulp and on a carboxylethylated pulp having 23 meq/100 g prepared by the method of aforenoted U.S. Pat. No. 5,667,637. Results are plotted on FIG. 5 and are summarized in Table 3 following.
TABLE 3
Surface
Total Carboxyl,
Surface Carboxyl,
Carboxyl,
Sample Type
meq/100 g
meq/100 g
%
Untreated
4
0.4
10
TEMPO Treated
24
˜9
˜37
TEMPO Treated
7-9
3.7
˜46
TEMPO Treated -
97
39
40
Example 5C
Carboxyethylated*
23
1.1
5
*Made according to the procedure described in Example 2, U.S. Pat. No. 5,667,637
Surface carboxylation as indicated by polyDADMAC adsorption should be indicative of adsorption/retention of cationic wet end additives such as cationic starch; cationic wet strength resins such as polyamide-epichlorohydrin, urea-formaldehyde, and melamine-urea-formaldehyde condensation products; and sizing agents such as alkylsuccinic acid and alkyl ketene dimer products. A higher retention of cationic starch will enable higher retention of precipitated calcium carbonate fillers. In addition, higher surface charge and higher retention of cationic additives will lead to faster drainage during sheeting.
EXAMPLE 7
Use of Alternative Oxidizing Agent to Hypochlorite
Buffer solutions were made up using varying amounts of Na 2 HPO 4 .7H 2 O and Na 3 PO 4 .12H 2 O in 100 mL water to give pH values as follows.
TABLE 4
Buffer
Na 2 HPO 4 .7H 2 O, g
Na 3 PO 4 .12H 2 O, g
pH
A
1.64
0.54
11.2
B
2.44
0.07
10.2
C
12.69
1.01
10.3
In similar manner another set of buffer solutions was made up using varying amounts of NaHCO 3 and Na 2 CO 3 in 100 mL water.
TABLE 5
Buffer
NaHCO 3 , g
Na 2 CO 3 , g
pH
D
2.31
0.25
9.2
E
0.64
0.51
9.7
F
1.11
1.73
10.0
A TEMPO-Stabrex ST70 (Nalco Chemical Co.) oxidation solution was made up using a ratio of 5 mg TEMPO to each 2.5 mL Stabrex. The TEMPO and a small amount of Stabrex were heated in running hot tap water until the TEMPO melted. The mixture was gently agitated until the solution was homogeneous. Then 2.5 g O.D. of a bleached northern softwood pulp was slurried in 100 mL of each of the buffer solutions maintained at 23° C. To this slurry was added at one time 2.5 mL of the TEMPO-Stabrex mixture. However, three samples were made using varying amounts of Stabrex and another to which 50 mg NaBr was added. Oxidation time was 41-45 minutes. The samples were vacuum filtered and washed with deionized water. They were then placed in a solution of 0.16 g NaBH 4 in 100 mL water at room temperature for 1 hour and again filtered and washed. Carboxyl content, D.P., and D.P. loss are shown in Table 6.
TABLE 6
Carboxyl Content and D.P. of Stabrex Treated Fiber
Sample
Buffer
Buffer
Stabrex,
Oxidation
Carboxyl,
D.P.
No.
Used
pH
mL
pH*
meq/100 g
D.P.
Loss, %
1
None
—
2.5
11.4-11.3
10
1035
39
2
A
11.2
2.5
11.0-10.2
17
755
56
3
B
10.2
2.5
10.5-9.3
23
750
56
4
D
9.2
2.5
9.2-9.0
23
1085
36
5
F
10.0
2.5
10.0-9.9
26
900
47
6
C
10.3
2.5
10.5-10.3
27
760
55
7
E
9.7
2.5**
10.3-9.9
26
930
45
8
E
9.7
0.5
9.9-9.8
5
1375
19
9
E
9.7
1.0
10.0-9.8
10
1255
26
10
E
9.7
5.0
11.0-10.0
52
645
62
*pH measured at the beginning and end of the oxidation period.
**This sample had 50 mg NaBr added to the TEMPO/Stabrex premix. Compare with Sample 5.
It is evident from the above table that Stabrex ST70 is an effective replacement for the NaOCl/NaBr secondary oxidant mixture. The addition of NaBr to the TEMPO/Stabrex mixture does not appear to increase its efficiency.
EXAMPLE 8
Properties of Handsheets Made from Carboxylated Cellulose Fibers
Six samples of carboxylated cellulose were prepared to investigate the effect of carboxyl content on papermaking properties. The samples were prepared by making a buffer solution of 15.1 g NaHCO 3 and 12.7 g of Na 2 CO 3 in 3.9 L of deionized water with 2.1 kg of ice. Into this was dispersed 150 g O.D. of bleached northern kraft softwood market pulp. The slurry pH was 9.7. A TEMPO oxidizing mixture was prepared by admixing 300 mg of TEMPO with 3.0 g NaBr and adding a small amount of 5.25% NaOCl solution. This premix was gently agitated until homogeneous and added to the pulp slurry. The balance of the NaOCl solution was added over several minutes. Varying total amounts of NaOCl solution were used with different batches to produce a set of samples having a spread of carboxyl contents. Four of the six samples of oxidized pulp placed in a reduction solution were with 10 g NaBH 4 made up with water to a total slurry weight of 2 kg. Time in the reducing solution varied from 30-45 minutes. Two additional samples were made using only 3.2 g of NaBH 4 with the time extended to 2 hours. Treatment conditions, carboxyl content, and D.P. are given in the following Table 7.
TABLE 7
Preparation of Pulps Having a Range of Carboxyl Content
MaOCl
Time to
Sample
Solution,
Washing,
NaBH 4 ,
Reduction
Carboxyl,
No.
mL
min.
g
Time, min
meq/100 g
D.P.
T-7
38
33
10
32
7
1670
T-10
60
17
10
30
11
1640
T-15
98
45
10
45
16
1580
T-20
135
25
10
30
23
1560
T-7M
38
49
3.2
130
9
1690
T-10M
60
23
3.2
120
12
1210
The six samples above, along with a sample of carboxyethylated pulp and one of untreated pulp were made into handsheets by TAPPI Method T-205. Sample T-10M was dried before making handsheets. The other samples were not dried following the reduction treatment. The carboxyethylated pulp was the same material used in Example 6. The samples were first refined in a PFI Refiner, available from Mølle, Hanjern, Oslo Norway for the number of revolutions set out below. The gap setting was 1 mm. Freeness was determined as Canadian Standard Freeness (CSF) using a tester available from Robert, Mitchell Co. St. Laurent, Quebec. These results are shown in Table 8 which follows.
TABLE 8
Canadian Standard Freeness
PFI Revs.
T-7
T-10
T-15
T-20
T-7M
T-10M
0
650
620
635
550
690
700
2000
530
485
480
395
535
560
2000
470
385
395
380
470
485
4000
325
325
320
280
370
370
Canadian Standard Freeness
PFI Revs.
Carboxyethylated
Untreated
0
620
710
1000
570
630
4000
470
500
8000
260
260
Handsheets made from each of the samples were evaluated by standard test methods. FIG. 6 is a plot of tensile index against sheet density. At a given density, the carboxyethylated fibers have generally higher tensile index values than the untreated control sheet, the exception being at the high density end where the differences may not be statistically significant. The carboxyethylated fiber is noticably below the control sample over the entire density range.
In all of the examples described to date the carboxylated cellulose will be in the form of a sodium salt. The cation can be changed readily by simple ion exchange; e.g., by treatment with a solution of a soluble calcium salt. Due to the unique proporties of these fibers there may be some advantage to replacement of sodium with a divalent cation in that there will be less swelling and a lower water retention value.
EXAMPLE 9
Properties of Sheets Made with Blends of Carboxylated and Untreated Fiber
A. Measurement of Drainage Rate and Preparation of Low Basis Weight Low Density Tissue Handsheets
The water used in all steps of these evaluations contained approximately 24 ppm sodium and 35 ppm calcium ions. About 30-31 g of pulp was refined in a PFI Refiner to 570±5 mL Canadian Standard Freeness. Nineteen grams (dry basis) of the refined pulp in a total of 2000 mL of water was placed in a British disintegrator (available as a British Pulp Evaluation Apparatus from Mavis Engineering, Ltd., London, England). 2.28 g of 12.5% Kymene 557H solution was added, and the slurry was disintegrated for 10 minutes. Kymene is a cationic polyamide-epichlorohydrin wet strength resin available from Hercules, Inc., Wilmington, Del. The resulting disintegrated pulp slurry was diluted to 19 L to form a 0.1% consistency slurry. The drainage rate of this slurry was measured by the amount of time taken to pass 300 mL of filtrate water, using a liquid slurry head height of 36 inches, through a 1.0 inch diameter circular handsheet forming wire containing 84×76 wires per inch. The forming wire was obtained from Albany International, 435 Sixth St., Menasha, Wis., 54952.
A 12 inch×12 inch deckle box was used to form handsheets of approximately 26 g/m 2 basis weight and approximately 240 kg/m 3 density on the forming wire described above. Five sheets were formed for each pulp. The sheets were not wet pressed. Dewatering of the handsheets was accomplished by passing the sheets still on the forming wire over a vacuum slit. The sheets were dried on a steam heated drum dryer and cured in an oven for one hour at 105° C. Wet burst strength of the sheets was measured on a Thwing Albert Model 1300-177 Wet Burst Tester manufactured by Thwing Albert Instrument Co., Philadelphia, Pa., 19154. Eight measurements were made for each pulp and the average calculated and taken as the wet burst strength.
B. Wet Burst Strength and Drainage Rate of Highly Carboxylated Fibers
Pulp Sample 5C from Example 5 was washed with a CaCl 2 solution followed by water to produce a highly carboxylated pulp with the cations substantially all calcium, and is designated Sample 5C1. Sample 5C1 was blended with northern softwood bleached kraft market pulp in a ratio of 10% Sample 5C1 and 90% northern softwood bleached kraft. This blend was used in the evaluations as described in Method (A.) above and was compared to a pulp consisting of 100% northern softwood market pulp. The pulp blend containing 10% highly carboxylated fibers showed a 17% decrease in drain time and slightly improved wet burst strength in comparison to the 100% northern softwood market pulp at equal freeness. Results are shown in Table 9.
TABLE 9
Drain Time
Pulp
(seconds)
Wet Burst (g)
Blend
166
1152
100% Northern Softwood Market Pulp
201
1136
C. Strength Properties of Carboxylated Fibers in Tissue Handsheets
A carboxylated fiber with 7 meq/100 g carboxyl level was prepared according to the procedure of Example 5 from northern softwood bleached kraft market pulp. Tissue handsheets were prepared according to the procedure, described in Method (A.) above, except that all pulps were refined to 470 mL Canadian Standard Freeness. The carboxylated pulp showed significantly higher wet burst and wet burst/dry tensile ratio. Table 10 describes the results obtained.
TABLE 10
Dry Tensile
Pulp
Wet Burst (g)
(Nm/g)
Carboxylated Northern Softwood Kraft
1799
76.4
Northern Softwood Kraft
1305
65.3
EXAMPLE 10
Use of Oxidizers or Oxidizers Followed by Reduction for Stabilization
Aldehyde and carbonyl substituent groups formed on the cellulose molecules during the TEMPO oxidation treatment may also be removed by treatment with certain oxidizing agents. Sodium chlorite is relatively inexpensive and has been found to be very satisfactory as the following example will show. TEMPO oxidized kraft wood pulp was prepared according to Example 1. From this material, samples were used for further treatment, one set for oxidation with sodium chlorite and the other for oxidation with sodium chlorite followed by borohydride reduction.
Technical grade sodium chlorite (0.5 g, 80% NaClO 2 ) was dissolved in a buffer solution of pH 3.6. Impurities in the NaClO 2 are known to be 5% Na 2 CO 3 , 2% NaClO 3 , and 13% NaCl. The buffer was formed using 23.1 mL of 0.4 M acetic acid solution, 3.7 mL of 0.2 M sodium acetate solution, and 60 mL deionized water. 15.6 g, (2.5 g dry weight) of the wet TEMPO oxidized pulp was then added. Treatment was continued for about 3 hours at room temperature (22° C.) and the product was then drained and washed.
To determine whether further stabilization was possible, half of the above stabilized cellulose was slurried in sufficient deionized water to which 0.08 g sodium borohydride was added to make 50 g of the slurry. Reduction was carried out for one hour at room temperature and the product then drained and washed. Analyses of the original pulp, and the three treated samples produced the following results shown in Table 11.
TABLE 11
Carbonyl,
Aldehyde,
Ketone,
Carboxyl,
Measured
Sample
mM/100 g
mM/100 g
mM/100 g
mM/100 g
D.P.
Untreated
0.0
—
—
4
1700
TEMPO
14.1
12.9
1.2
25
300 1
Oxidized
TEMPO +
1.2
—
—
39
760 2
NaClO 2
TEMPO +
0.0
—
—
39
1150 1
NaClO 2 +
NaBH 4
1 D.P. measured in —COONa form
2 D.P. measured in —COOH form
It should be noted that in all earlier examples, D.P. was measured with the carboxylated cellulose in the form of a sodium salt. D.P. measured in the free acid form is invariably lower. A rigorous correlation between free acid form D.P. and sodium salt D.P. does not exist, for reasons that are poorly understood. It is believed that, in some cases, there may be some cationic substitution on the carboxyl groups even though the pH at which samples were prepared should normally preclude this. However, there are instances when this explanation does not appear to be fully satisfactory. In all examples following, the form in which D.P was measured will be indicated.
Carbonyl group determination was made by treating the samples with an oxidation reagent (hydroxylamine) followed by measurement of nitrogen content.
No attempt was made in this example to optimize reaction conditions. However, it is immediately evident that the sodium chlorite treatment significantly reduced carbonyl substitution. The small residual amount of carbonyl was effectively removed by the subsequent borohydride treatment. D.P. measurement in cuene solvent is one very useful measurement of product stability. Generally, D.P. measured as a sodium salt will be somewhat higher than that when the product is measured in the free acid form. Stability of the above products in the alkaline cuene solvent was markedly improved by the stabilization treatments.
EXAMPLE 11
Oxidative Stabilization at Different Temperatures
In order to further optimize reaction conditions, carboxylated cellulose of Example 1 was treated with sodium chlorite at 40°, 60°, and 80° C. A 2.0 g (dry weight) sample of the TEMPO treated pulp was suspended in a citrate-phosphate buffer at pH 3.0. To the suspension was added 0.17 g of 80% NaClO 2 and deionized water to make a total weight of 80 g. The chlorite usage was chosen to be in an approximate 5:1 molar ratio to the assumed aldehyde content of the TEMPO oxidized pulp. Presumed aldehyde content was based on the sample described in Table 11. Oxidation was allowed to proceed for 30 minutes, whereafter the sample was drained and washed. Cuene D.P. measurements were made on the free acid form of the samples and found to be as follows.
Reaction Temperature, ° C.
D.P.
40
745
60
845
80
865
Within the time period chosen the 60° C. temperature clearly produced a more stable product. Reaction at 80° C. gave only marginally greater stability.
EXAMPLE 12
Effect of Time on Oxidative Stabilization
To investigate the effect of time on stabilization of the product, a set of experiments was carried out at 70° C. with other conditions similar to those set out in Example 11, except that pH was raised to 3.2. Reaction times were 15, 30, and 60 minutes. As an additional experiment, one set of samples was made with a 10:1 ratio of chlorite to presumed aldehyde content. Results were as follows as seen in Table 12. All samples were converted to the sodium salt (—COONa) prior to D.P. measurement.
TABLE 12
Reaction Time,
Ratio of Chlorite:Pre-
min
sumed —CHO
Measured D.P.
15
5:1
1035
30
5:1
995
60
5:1
995
30
10:1
985
60
10:1
1080
It is apparent that, under the present conditions, an extended reaction time does not result in significantly greater D.P. stabilization. Presumably the oxidation reaction has moved to near completion within the first 15-30 minutes.
EXAMPLE 13
Effect of Sodium Chlorite Concentration and Consistency on Stabilization
Another set of experiments was made to determine whether solution concentration of sodium chlorite and fiber consistency had a significant effect on D.P. stability. Conditions, except as noted in Table 8 which follows, were similar to those described in Example 12.
TABLE 13
Sodium
Ratio NaClO 2 :
Sample Consis-
Measured D.P.
Chlorite, g/L
—CHO
tency, %
—COOH
—COONa
1.6
5.0
2.5
715
1025
3.2
5.0
5.0
790
1035
6.4
5.0
10.0
905
1120
9.6
20.0
5.0
1000
1175
D.P. shows a linear relationship with sodium chlorite concentration in the aqueous reaction medium when measured either on the sodium salt or the free acid form of the product. The increasingly higher concentration of sodium chlorite in the aqueous phase resulted in the higher measured D.P.
EXAMPLE 14
Effect of pH on Oxidative Stabilization with Sodium Chlorite
A set of samples was made similar to those of Example 12 except that pH was changed in four steps between 2.8 and 4.0. Results are seen in Table 14.
TABLE 14
Oxidation
Measured D.P.
Reaction pH
—COOH
—COONa
2.8
735
1010
3.2
715
995
3.6
805
970
4.0
840
975
EXAMPLE 15
Properties of Hand Sheets Made with Oxidatively Stabilized Carboxylated Cellulose
A carboxylated fiber with 10 meq/100 g carboxyl level was prepared according to the procedure of Example 10 from the same northern bleached softwood kraft market pulp except that the chlorite stabilization was carried out at room temperature overnight (about 16 hours). Tissue handsheets were prepared according to the procedure described in Method (A.) of Example 9, except that all pulps were refined to 530 mL Canadian Standard Freeness. The carboxylated pulp showed a significantly higher wet burst and wet burst/dry tensile ratio as seen in Table 15.
TABLE 15
Pulp Sample
Wet Burst, g
Dry Tensile, Nm/g
Northern softwood kraft
1280
67.5
Carboxylated northern softwood kraft
1832
78.2
The inventors having herein set out their best mode of practicing their invention, it will be apparent to those skilled in the art that many variations are possible that have not been described in the examples. It is their intent that these variations should be included within the scope of the invention if they are encompassed within the following claims. | The invention is directed to a method of making carboxylated cellulose fibers whose fiber strength and degree of polymerization is not significantly sacrificed. The method involves the use of TEMPO (2,2,6,6-tetramethylpiperidinyloxy free radical) as a primary oxidant and a hypohalite salt as a secondary oxidant in an aqueous environment. Preferably the oxidized cellulose is then stabilized against D.P. loss in alkaline environments and color reversion with a reducing agent such as sodium borohydride. Alternatively it may be treated with an oxidant such as sodium chlorite. The method results in a high percentage of carboxyl groups located at the fiber surface. The product is especially useful as a papermaking fiber where it contributes strength and has a higher attraction for cationic additives. The product is also useful as an additive to recycled fiber to increase strength. The method can be used to improve properties of either virgin or recycled fiber. It does not require high α-cellulose fiber but is suitable for regular market pulps. | 3 |
BACKGROUND OF THE INVENTION
The instant invention relates to an auxiliary extension member and support frame for a vehicular mounted aerial ladder assembly.
Vehicular mounted ladders, towers, and aerial lift means of various types are generally disclosed in the prior art as being comprised of the following major design types. First, ladder or tower aerial lift assemblies are exemplified by those such as taught in U.S. Pat. No. 2,936,848 to Hall, dated May 17, 1960, as well as U.S. Pat. No. 3,489,244 to Rickrode et al., dated Jan. 13, 1970, and U.S. Pat. No. 3,621,935 to Bode, dated Nov. 23, 1971. The elevation and lifting means disclosed in the aforementioned patents range from manually operable to motorized aerial lift units which were primarily designed for use by utility line installers and maintenance personnel for erecting and repairing overhead electrical transmission lines and the like, in addition to being employed by tree trimming crews, as well as construction workers and painters in accomplishing various elevated operations. As further exemplified by the aforementioned patents, said ladder or tower aerial lift assemblies may also have affixed thereto, at the uppermost terminal end thereof, a work platform which may be stationary, as shown in Bodie, or arcuately adjustable with regard to maintaining a parallel relation to the horizontal plane, as shown in Hall, or, as shown in Rickrode et al, have no platform at all.
A second general type of aerial lift design are those primarily comprised of a "boom and bucket" assembly, which may or may not be vehicular mounted, and may or may not incorporate ladder features, exemplary disclosures of which are as shown in U.S. Pat. No. 3,584,703 to Lane, dated June 15, 1971, U.S. Pat. No. 3,625,307 to Siefermann et al, dated Dec. 7, 1971, and U.S. Pat. No. 3,777,845 to Ashworth, dated Dec. 11, 1973. Bucket levelling features are also normally incorporated, generally comprised of either a hydraulically activated mechanical lever assembly operable through a series of pivot points, or secondly, simple gravitational levelling means provided by pivotal suspension of said bucket from the upper end of said boom either with or without bucket stabilizing means. Aerial lift equipment of this second general design is usually larger in size and more expensive than the first general type heretofore described, and is primarily and popularly employed in fire fighting and rescue operation types of activities.
Other aerial lift means disclosures, which may be classified in one or the other categories of the two main general designs heretofore indicated, but which teach additional aspects of the art not otherwise shown, include the following: U.S. Pat. No. 2,666,417 to Harsch, dated Jan. 19, 1954, which shows a rotatably and arcuately positionable hydraulically operated two member telescopic boom having a man-carrying cage pivotally affixed to the upper terminal end thereof, whereby said cage is maintained in a horizontal configuration by means of a double-acting hydraulic motor linkably connecting said cage and the upper terminal end of said boom so that as the boom operates said motor automatically extends and retracts a piston in direct relation to the tilt of the boom, and said cage is thereby automatically maintained in a horizontally level position. A subsequent disclosure by Harsch, in U.S. Pat. No. 2,786,723 dated Mar. 26, 1957, shows a similar structure to his earlier disclosure cited supra, but teaching a new method of employing a hydraulic cylinder unit to correlate the horizontal configuration of the cage with the pivotal movements of the boom such that said cage is automatically maintained in a level disposition at all angular articulations of said boom. Another disclosure in the aerial lift art teaching less sophisticated employment of a hydraulic piston to maintain a horizontally level cage configuration is that as shown in U.S. Pat. No. 2,724,620 to Johnson et al., dated Nov. 22, 1955.
The disclosure set forth in U.S. Pat. No. 2,815,250 to Thornton-Trump, dated Dec. 3, 1957, shows an aerial lift device comprised to two pivotally connected boom sections whereby a 180° horizontally arcuate deflection capability is substantially provided for the man-carrying cage assembly pivotally affixed to the upper terminal end of the second boom section thereof, with a bell crank linkage extending from the boom structure junction to the cage through which said cage is maintained essentially in a horizontal position irrespective of the swinging movement of said booms. The disclosure by Garnett, in U.S. Pat. No. 3,196,979 dated July 27, 1965, shows means for controlling horizontal position of a man-carrying basket member pivotally affixed by means of a yoke to the end of a telescoping boom, but additionally shows a novel arrangement whereby the basket carrying arm members of the aerial lift device yoke are also pivotal rearwards whereby the transport position is one in which said basket member and yoke are folded back and said basket member rests in a stowed position upon the inner telescoping boom section. In U.S. Pat. No. 3,332,513 to Weibe, dated July 25, 1967, a mobile scaffold is shown wherein the cage member thereof remains substantially horizontal by means of a set of double-bar/double-arm linkages.
The art disclosed by Hall in U.S. Pat. No. 3,572,467 dated Mar. 30, 1971, shows a vehicular mounted telescopically extensible ladder assembly with a personnel platform pivotally affixed thereto and linkably interaffixed to a slave piston and cylinder unit whereby said platform may be stabilized or swung. Hall also teaches stowing of the retracted aerial unit rearward in the transport vehicle. A similar disclosure by, Garnett, in U.S. Pat. No. 3,767,007 dated Oct. 23, 1973, shows a pivotally mounted basket member affixed to the upper terminal end of an extensible ladder, but with the aerial unit facing vehicularly forward in the retracted stowed transport configuration, and a shock absorber type of assembly provided as a damping means to prevent sudden changes in said basket member configuration when said aerial unit is operably positioned.
Two additional disclosures showing aerial lift features of considerable interest are those set forth in U.S. Pat. No. 3,625,304 to Siefermann et al, dated Dec. 7, 1971, and the other being U.S. Pat. No. 3,710,893 to Hippach, dated Jan. 16, 1973. The Siefermann et al. disclosure shows a vehicular mounted aerial ladder assembly with a pivotally affixed cage at the upper end thereof, whereby either an electric or hydraulic power source located on the ladder provides means to automatically maintain said cage in an upright configuration relative to the horizontal position regardless of any change in incline of said aerial ladder assembly. The Hippach patent, however, shows an extendible boom and ladder assembly with a pivoted basket depending from a yoke extension affixed to the end of said boom, and further having a relatively short two-section ingress and egress ladder leading from the upper end of the main ladder into the pivotally depending basket.
It should be understood that some of the features of the instant invention have, in some cases, structural and functional similarities to teachings separately set forth in the prior art disclosures heretofore cited and briefly discussed. However, as will hereinafter be pointed out, the instant invention is distinguishable from said earlier inventions in one or more ways in that the present invention has utility features and new and useful advantages, applications, and improvements in the art of vehicular mounted articulated aerial lift and ladder assemblies not heretofore known.
SUMMARY OF THE INVENTION
It is the principal object of the present invention to provide a vehicular mounted, multiply-articulated aerial lift and ladder assembly comprised of pivotally connected motor driven main and auxiliary ladder members with a pivotally connected partially enclosed man-carrying platform member affixed to the end thereof and incorporating design features which provide for a combination of mechanically automatic as well as mechanically powered horizontal levelling capabilities for said platform member, wherein, hydraulically activated longitudinal extension of the main ladder member or hydraulically activated arcuate deflection of the auxiliary ladder member will not affect the horizontal orientation of said platform member, however, upon hydraulically activated arcuate deflection of said main ladder member occurring the horizontal orientation of said platform assembly may be continually compensated for and maintained by simultaneously activating an electrical motor driven jack screw levelling means during vertically arcuate displacement of said main ladder member to the desired operative angular elevation relative to the ground plane.
It is another object of the present invention to provide remotely controlled motor driven mechanically articulated motion capabilities which will enable the safe and accurate positioning of a man within said platform member at an extended aerial location within the workable range of said lift and ladder assembly.
It is a further object of the present invention not only to provide a lift and ladder assembly which is vertically extensible, but additionally is horizontally extensible and rotatably displaceable.
Still another object of the present invention is to provide a sturdy vehicular mounting and support structure assembly for said lift and ladder assembly which will enable optimum utilization of vehicle cargo-carrying space and capacity.
It is yet another object of the present invention to provide a sturdy vehicular lift and ladder assembly mounting and support structure assembly which is both easily installed and easily removed.
An additional object of the present invention is to provide a sturdy vehicular mounting and support structure assembly, which, in combination with said lift and ladder assembly, will permit the ease of loading tools within, and mounting of, the platform member of said lift and ladder assembly while the same is in stowed position upon the vehicle.
A further object of the present invention is to provide a multiply articulated aerial lift and ladder assembly and vehicular mounting support structure which is relatively simple and less expensive than currently available equipment having comparable capabilities.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a side elevation of an auxiliary extension member installed upon a vehicular mounted aerial ladder assembly, with the unit being shown in a stowed vehicular transport position upon and secured to the stowed ladder support frame.
FIG. 2 is an end elevation of the view shown in FIG. 1 as seen on the line 2 -- 2 thereof.
FIG. 3 is an enlarged fragmentary side view of the auxiliary extension member as shown in FIG. 2 and seen on the line 3 -- 3 thereof.
FIG. 4 is a simplified side elevation of the vehicular mounted unit as shown in FIG. 1, but also showing phantom views of various positions of elevation and extension of said unit between the stowed vehicular transport position and maximum operational elevation.
FIG. 5 is a detailed enlarged fragmentary side elevation of two of the elevated and extended views of said unit as shown in FIG. 4.
FIG. 6 is a schematic diagram of the integrated electrical and hydraulic circuits whereby the articulating function powering means for said unit are activated and controlled.
FIG. 7 is an enlarged plan view of the auxiliary extension member platform, as seen along the line 7 -- 7 of FIG. 3, showing locations thereon of the electrical and hydraulic circuit control switches.
DETAILED DESCRIPTION OF THE INVENTION
Referring to FIG. 1, the present invention, shown in a stowed vehicular transport position, comprises an auxiliary extension member 10 which is pivotally affixed to the extensible ladder section 12 of an aerial ladder assembly 14, which in turn is rotatably mounted upon a main support frame 16 detachably installed upon an exemplary service vehicle 18, with aerial ladder members 20 of said assembly 14 extending rearward of said vehicle 18 and resting upon the horizontal support member 22 between flange ears 24 of the stowed ladder support frame 26 which is likewise detachably affixed to said vehicle 18, with said auxiliary extension member 10 being secured for transport by means of latch assembly 28.
Referring again to FIG. 1 to describe in greater detail the component parts of this invention as well as explain the operation thereof, the auxiliary extension member consists primarily of two functional groups, each being extensibly operable by separate and independently controlled drive means. The first functional group is made up of a linked parallel bar assembly comprising an auxiliary ladder section 30 and a set of parallel members 32. The auxiliary ladder section 30 is pivotally connected at the upper stowed position ends thereof to the upper end of extensible ladder section 12 at pivot points 34, while each of the parallel members 32 is respectively pivotally connected at the upper stowed position ends thereof at pivot points 36 to bracket members 38 which are in turn stationarily affixed to extensible ladder section 12 such that the respective center-to-center distances between pivot points 34 and 36 on either side of extensible ladder section 12 are dimensionally equal. The lower respective ends of ladder section 30 are pivotally connected to plates 40 at pivot points 42, while the lower respective ends of parallel members 32 are pivotally connected to plates 40 at pivot points 44, such that the respective center-to-center distances between pivot points 42 and 44 are equal to the center-to-center distances between pivot points 34 and 36. With the first functional group having a pivotally linked construction as heretofore described, one is thereby enabled to longitudinally extend the extensible ladder section 12 and/or arcuately extend said first functional group assembly of the auxiliary extension member by means of hydraulic piston 46 pivotally attached at the upper stowed position end thereof to bracket member 38 on extensible ladder section 12 and, at the piston rod end thereof is pivotally attached to bracket 48 which is stationarily affixed to the auxiliary ladder section 30, and in so doing, the second functional group, comprised of a pivotally affixed man-carrying platform assembly, will essentially maintain a configuration whereby the base of said platform remains horizontal and parallel to ground level 50.
The second functional group of the auxiliary extension member 10 is made up of a platform assembly comprised of a platform base 52 which has affixed thereto a partially enclosing frame work structure 54 which in turn supports a work bench member 56 wherein are mounted the power and control switches to operate the integrated electrical and hydraulic circuits whereby the auxiliary extension member 10 and the aerial ladder assembly 14 are articulated to position a man at an elevated and/or extended work position. The work bench member 56 also provides a working surface as well as providing a place to stow and carry tools aloft. The platform assembly is pivotally attached to plates 40 at pivot points 58 by means of brackets 60 stationarily affixed to the platform base 52, as well as also being pivotally attached at pivot point 62 to an electric motor driven jack screw 64 by means of bracket 66 stationarily affixed to a frame work structure member. The motor end of jack screw 64 is pivotally connected at pivot point 68 to a mounting member 70. By means of this second functional group of the auxiliary extension member, being pivotally connected as heretofore described, an operator in the platform assembly, by activating the electrically powered jack screw 64, is enabled to continuously and simultaneously tilt and maintain the base of said platform in a horizontal position relative to the ground level 50 upon vertically arcuate displacement, either up or down, of the aerial ladder assembly 14 through its full range of vertically arcuate displacement. Therefore, the mechanically linked pivotal combination of the aforementioned two functional groups, powered by their respective drive means, enables full control by an individual occupying the platform assembly, of the orientation and configuration of the platform assembly irrespective of whether the auxiliary extension member 10 is arcuately extended, or the aerial ladder assembly 14 is extended or retracted, arcuately displaced up or down in a vertical plane, or rotationally displaced in a horizontal plane by means of the rotary deck plate member of the aerial ladder assembly, or a series of movements comprised of a compound combination of the aforementioned articulations. In addition to the aforementioned adjustability of the angle of the extensible aerial ladder assembly 14 relative to platform base 52, the angular positioning of auxiliary ladder section 30 relative to the assembly 14, and the levelling of platform base 52 to a desired horizontal position by means of jack screw 64, it will be seen from the foregoing that an important feature of the invention comprises the fact that, after an operator has established the desired angle of the assembly 14 at which he wishes to work, he may thereafter vary the angle of the auxiliary ladder section 30 relative to the upper end of assembly 14 by activating hydraulic piston 46 in the desired direction and the platform base 52 automatically will remain horizontal by the function of the linkage assembly comprised of auxiliary ladder section 30 and parallel members 32.
Additionally shown in FIG. 1 are the main support frame 16, the stowed ladder support frame 26, and the latch assembly 28 which is affixed to the stowed ladder support frame main vertical post member 72. Support frame members 16 and 26 enable the combined aerial ladder and auxiliary extension member assemblies to be operationally installed upon and transported by an exemplary service vehicle 18 in such a manner so as to insure optimum utility of available vehicle cargo space and to further provide easy access to, and personnel entry of, the platform assembly. The support frame assemblies are constructed of a suitable tubular stock material sufficient in size and weight to provide for sturdy and safe transport and aerial ladder and auxiliary extension member operation. The main support frame 16 is further provided with access steps 74 and a catwalk 76 for ease of personnel entry to or from the aerial ladder assembly in emergency or assist situations. Both of the support frame assemblies are affixed to the service vehicle body by means of bolts 78 for ease of installation and removal as it has been generally found that aerial ladder assemblies of the type herein shown have an operational life considerably in excess of that of the vehicle upon which they are normally installed.
The stowed ladder support frame shown in FIG. 1, as it will be noted by reference to FIG. 2, is installed so as to support the aerial ladder assembly and auxiliary extension member to one side of the service vehicle cargo bed 80, the purpose being to provide for ease of access to, and maximum utility of, available cargo space. Attached to the stowed ladder support frame is latch assembly 28, comprised of a mounting bracket 82, foot release lever 84, a return spring 86, and pivoted catch 88, wherein the catch 88 engages the mounting member 70 to secure the auxiliary extension member when in the stowed transport position as shown.
It should further be noted, as shown in FIG. 1, the hydraulic piston 46 is supplied with fluid from the main hydraulic reservoir of the aerial ladder assembly through hydraulic line 90 which is automatically paid out from the spring loaded hose drum 92 upon ladder elevation and extension, and automatically rewound upon ladder lowering and retraction.
The auxiliary extension member 10 as disclosed in FIG. 1 may be constructed of metal, plastic, wood, or any other suitable materials or a combination thereof.
In FIG. 2 an end view of the side elevation shown in FIG. 1, as seen along the line 2 -- 2 thereof, is detailed wherein there is seen the lateral configuration of support frame members 16 and 26 installed upon the exemplary service vehicle 18, as well as the configuration of the auxiliary extension member 10 affixed to the aerial ladder assembly when both of the same are in the stowed vehicular transport position.
In FIG. 3 a fragmentary enlarged side elevation as shown in FIG. 1, but seen along the line 3 -- 3 of FIG. 2, is presented to disclose greater structural and assembly detail of the auxiliary extension member as well as the stowed ladder support frame 26 and the latch assembly 28 affixed thereto.
The alternate disposition views shown in FIG. 4 present a series of simplified side elevations wherein are seen exemplary elevation and extension configurations which are possible with the vehicularly installed aerial ladder assembly having an auxiliary extension member affixed thereto in accordance with the foregoing descriptions as well as will those hereinafter set forth. The initial position is that of the ladder assemblies in the vehicular transport position as they are when the equipment arrives at a job site. The position seen in view A of FIG. 4 shows the aerial ladder assembly after having been arcuately elevated through a relatively small angle of vertical deflection with no aerial ladder extension. At this point a person occupying the platform assembly can activate the jack screw motor to extend the jack screw 64 and bring the platform base 52 into horizontal alignment relative to the ground level 50. It should be noted that a reasonably skilled person would be able to simultaneously coordinate the operation of multiple control switches and maintain his relative horizontal alignment while performing simultaneous multiple articulation functions with the ladder assemblies.
The position seen in view B of FIG. 4 shows the aerial ladder assembly after having been arcuately elevated through a moderate angle of vertical deflection and aerial ladder assembly extension, in addition to arcuate displacement of the auxiliary ladder section 30 as well as extension of the jack screw 64, wherein the jack screw extension has been employed to maintain position of the platform assembly in a relative horizontal configuration to ground level 50. The position seen in view C of FIG. 4 is similar to that seen in view B, except that the entire ladder assembly has been extended through its maximum intended vertically arcuate deflection to the maximum elevation, and showing the jack screw 64 at maximum extension to maintain the platform assembly in a horizontal reference parallel to ground level.
In FIG. 5 there is presented enlarged fragmentary alternate detail views corresponding to the auxiliary extension member configurations shown in the simplified views A and C of FIG. 4, wherein is seen exemplary different configurations of the extension and pivotal linkages whereby the platform assembly may be horizontally maintained as heretofore described.
The diagram shown in FIG. 6 is a schematic of the integrated electrical and hydraulic circuits by which the ladder assembly 14 is powered and directionally displaced, which circuits incorporate a dual location control console system whereby the aerial ladder assembly may be selectively positioned by either an operator occupying the platform assembly through means of the first control console directional displacement switches mounted in the work bench member 56 thereof as shown in FIG. 7, or alternately by a remote operator through means of a set of second control console directional displacement switches not shown, but, however, positioned at a ground level mounting upon the service vehicle 18. The second control console at a ground level location additionally provides, by means of a safety over-ride circuit, the ability to cut out power to the platform location first control console and thereby enable ground position displacement of the ladder assembly in the event of an emergency or rescue situation, such as a platform positioned operator in some manner being injured or otherwise incapacitated.
The main power switch SW-1, as shown in the FIG. 6 circuit schematic, is a simple pull "on" and push "off" switch which when in the "on" position provides positive circuit energizing of the control console directional displacement switches SW-2, SW-3, SW-4, SW-5, and SW-6 through Line A as also shown in the FIG. 6 circuit schematic. Switch SW-2 is, as are all remaining switches in the control circuit, a double-pole/double-throw/spring return to center switch, and is employed to energize positive and negative circuits which activate the bi-directional jack screw electrical motor for maintaining horizontal control of the platform assembly upon vertically arcuate displacement of the aerial ladder assembly 14. When held in closed position in one direction SW-2 energizes the forward windings in the bi-directional jack screw motor and the screw 64 is extended out from the jack housing, as indicated by "O" on the schematic. When SW-2 is held in the closed position in the opposite direction the reverse windings in the bi-directional jack screw motor are energized and the screw 64 retracts as indicated by "I".
Vertical arcuate up and down displacement of the aerial ladder assembly 14 is accomplished with switch SW-3, which when activated in the elevation direction energizes a solenoid switch on the electric motor which drives the hydraulic pump while concurrently energizing the solenoid which opens the normally closed elevation safety valve thereby allowing pressurized hydraulic fluid entry to the elevation cylinder and extension of the lift piston which also thereby effects vertically arcuate elevation of the aerial ladder assembly. Activating switch SW-3 in the lowering direction energizes the solenoid which opens the normally closed elevation safety valve while concurrently energizing that solenoid which opens the pump mounted release valve, thereby releasing pressure in the elevation cylinder and enabling the lift piston to retract which also thereby effects vertically arcuate lowering of the aerial ladder assembly.
Horizontal left and right rotary displacement of the aerial ladder assembly 14 is controlled by switch SW-4, which when activated in one position energizes the solenoid switch on the electric motor which drives the hydraulic pump while concurrently energizing the solenoid which opens the normally closed left rotation valve thereby admitting pressureized hydraulic fluid to the bi-directional hydraulic rotation motor and effecting a rotary left directional displacement of the aerial ladder assembly. Activating switch SW-4 in the opposite direction simultaneously energizes the hydraulic pump electric motor solenoid as well as the solenoid which opens the normally closed right rotation valve thereby admitting pressurized hydraulic fluid to the opposite side of the bi-directional hydraulic rotation motor and effecting a rotary right directional displacement of the aerial ladder assembly.
The switch employed to control extension and retraction of the aerial ladder assembly 14 is SW-5, which when activated in the extension position energizes the hydraulic pump motor solenoid and concurrently the solenoid which opens the extension valve of an extension and retraction hydraulic motor, thereby enabling pressurized hydraulic fluid to rotate said extension and retraction hydraulic motor in the direction of extension and operate the chain drive whereby the aerial ladder assembly is extended. Activation of SW-5 to the retraction position simultaneously energizes the hydraulic pump motor solenoid and the retraction valve solenoid of the extension and retraction hydraulic motor, thereby enabling pressurized hydraulic fluid to rotate said extension and retraction hydraulic motor in the direction of retraction and operate the chain drive whereby the aerial ladder assembly is retracted.
The last control switch is SW-6 and is employed to operate the extension ladder hydraulic piston 46 for accomplishing arcuate displacement of the platform assembly by means of the auxiliary extension member 10. Activation of switch SW-6 in one direction energizes the hydraulic pump motor solenoid and concurrently energizes the solenoid which opens the normally closed hydraulic piston 46 safety valve thereby enabling pressurized hydraulic fluid to enter the cylinder of piston 46 and cause said piston to extend, and also thereby effecting arcuate extension of the platform assembly. Activation of switch SW-6 in the opposite direction energizes the normally closed hydraulic piston 46 safety valve solenoid and opening said safety valve, as well as simultaneously energizing that solenoid which opens the pump mounted release valve, thereby enabling pressurized hydraulic fluid to escape from the cylinder of piston 46, and upon the resultant retraction of said piston likewise effect arcuate retraction of the platform assembly.
The view seen in FIG. 7 is an enlarged top plan drawing of the platform assembly as shown along the line 7 -- 7 of FIG. 3, and shows the relative positions and identifications of the various control switches heretofore described and discussed.
While the invention has been described and illustrated in its several preferred embodiments, it should be understood that the invention is not to be limited to the precise details herein illustrated and described since the same may be carried out in other ways falling within the scope of the invention as illustrated and described. | A vehicular mounted, multiply-articulated aerial lift and ladder assembly comprised of a terminally affixed and partially enclosed platform member pivotally connected to a linked parallel bar assembly having a ladder section as the outward longitudinal element thereof, wherein the linked parallel bar assembly is in turn pivotally connected to the uppermost end of the extension member of a vertically displaceable dual-membered main extension ladder assembly which at the lower end thereof is pivotally attached to a horizontally rotatable platform affixed to a supporting structure upon the vehicle, the entire combined aerial lift and ladder assembly heretofore described having displacement powering means entirely operable from a control panel within the platform member, whereby a person occupying the platform may accurately position and maintain himself in an extended aerial work location within the horizontally oriented platform member. Design features of the aerial lift and ladder assembly incorporate both automatic and motor powered horizontal levelling provisions for the platform member. | 1 |
FIELD OF THE INVENTION
The present invention relates to protection of the surfaces of various structures against marine fouling, and more particularly to bis-trialkylstannyl derivatives of chlorinated polycyclic dicarboxylic acid, to a method for producing same, and to compositions for antifouling coatings.
BACKGROUND OF THE INVENTION
It is well known that the accumulation of a great amount of a biomass on the surface of offshore installations, platforms and plies, as well as on ships' bottoms, causes serious biological problems and causes substantial damage. One effective way to protect various surfaces against marine fouling is the use of chemicals, namely, the application of protective polymer coatings containing antifouling agents.
An important stage in solving the fouling problem is the search for more effective antifouling agents. Organotin compounds are known to be widely employed as antifouling toxins in various polymer coatings.
The prior art antifouling polymer compositions contain, as the active component, organotin carboxylate compounds of the general formula R--COOSn(n--C 4 H 9 ) 3 (wherein R is an alkyl, aryl), CCl═CCl--COOSnR 3 (wherein R is an alkyl), (cf. Japanese Pat. Nos. 1,103, 1969, Cl. 24F1; 26,437, 1970, Cl. 24F1; 31,553, 1970, Cl. 24F1).
There has been proposed an antifouling composition with organotin toxins of the R 3 SnX type (wherein R is an alkyl, aryl; X is a halogen) (cf. Japanese Pat. No. 26,438, 1970, Cl. 24F2).
The "Takeda Chemical Ind. Ltd" company has developed an antifouling polymeric paint containing, as the toxin, a synergistic mixture of aminochloronaphthoquinone, Cu 2 O and hexabutyldistannoxane [(n--C 4 H 9 ) 3 Sn] 2 O or trialkylfluorostannane R 3 SnF and bis-trialkylstannylmaleate R 3 SnOOC--CH═CH--COOSnR 3 (cf. U.S. Pat. No. 3,615,744; Cl. 106/15 CO9d5/14; 1971).
The "Plastic Molders Supply Inc" company has proposed a composition for protecting ships' bottoms and offshore installations against fouling, based on a polyester resin and an organotin compound (12-20%) of the R 3 SnF type, wherein R is an alkyl, aryl (cf. French Pat. No. 2,055,996; Cl. CO9d5/00 1971).
To impart antifouling properties to paints, the "Caddsec Chemical Works Inc." company of the United States has proposed a composition containing organotin sulfur-containing compounds of the general formula [R 3 SnOOC(CH 2 ) n S] 2 CH 2 , wherein R is an alkyl (cf. U.S. Pat. No. 3,463,644; Cl. 106-15 (A61k); 1960).
A patent has been granted for a polymer material for an underwater antifouling coating, which contains high-molecular organotin compounds obtained by full or partial introduction of compounds of trialkyl(phenyl)tin, amines, isocyanates, etc. into the carboxyls of a dimeric acid (cf. Japanese Pat. No. 1,224/73; Cl. 24F21 (COd5/16), 1973).
Also proposed as antifouling agents have been organotin compounds of the (n--C 4 H 9 ) 3 SnXR type (wherein R is a halogenated phenyl, X=O,S) (cf. Japanese Pat. No. 48-41,258; Cl. 24F1, 1973) and of the (n--C 4 H 9 ) 3 SnX type (wherein X is toluene sulfoanilide) (cf. Japanese Pat. No. 37,491; Cl. 24f2, 1972).
There has been proposed a method for producing biostable paints and varnishes by way of modification of known polymers with organotin methacrylate, maleates and their polymers in combination with a binder, a filler, a solvent and other additives (cf. U.S.S.R. Inventor's Certificate No. 210,296; Cl. 22h 10/01, 39b, 22/01 (CO9d, CO8f), 1967).
Also known are antifouling paints based on bis-(triphenyl-tin)-monochloromaleinate (C 6 H 5 ) 3 SnOOC--CH═CCl--COOSn(C 6 H 5 ) 3 (cf. Japanese Pat. No. 51-41,648, 1976), compounds of the (C 6 H 5 ) 3 SnX type, wherein X=OH, F, Cl, OOCCH 3 , OOCCH 2 Cl, OSn(C 6 H 5 ) 3 or compounds of the formula (C 6 H 5 ) 3 SnOOC--CH(Br)COOSn(C 6 H 5 ) 3 (cf. Japanese Pat. No. 51-109,934, 1976).
The above prior art organotin compounds used as antifouling agents suffer from a number of serious disadvantages, namely;
the process of producing these compounds is complex and involves numerous steps. Raw materials are scarce or unavailable.
Most organotin compounds are powders or solids with a pungent odor, which necessitates additional expenses and precautions when they are introduced into paints.
Organotin and chlororganic compounds are, when taken separately, less effective toxins against marine fouling. Halogen-containing agents suppress growth of organisms primarily of vegetal origin, while organotin toxins prevent accumulation of a biomass predominantly of animal origin.
The prior art organotin compounds are highly effective as antifouling agents, however their activity is short lived because of the high rate of their leaching out in sea water.
The prior art compounds are poorly soluble and compatible with known film-forming polymers, pigments and fillers used in antifouling coatings.
The prior art antifouling coatings with the above organotin compounds are not adequately adhesive and strong, and their weatherproof characteristics are poor.
SUMMARY OF THE INVENTION
It is, therefore, an object of the present invention to provide novel chlorinated organotin compounds featuring high antifouling activity, as well as antifouling polymer compositions based thereon.
According to the invention, there are proposed bis-trialkylstannyl derivatives of chlorinated polycyclic dicarboxylic acids, of the general formula (I) ##STR2## wherein R is a lower alkyl, R'=H,CH 3 and n=0,1.
Compounds of the above formula are novel substances.
It has been established that these compounds are biologically active and can be used as antifouling agents in protective polymer coatings.
DETAILED DESCRIPTION OF THE INVENTION
The proposed compounds are more effective antifouling agents than those known in the prior art and suppress growth of biomasses of both vegetal and animal origin. This property is due to the presence in the molecule of said compounds of chlorinated cyclic fragments with two organotin carboxyls. Another advantage of the proposed compounds is the low rate of their leaching out in sea water, which provides for a longer life of coatings based on them.
The most effective compounds are bis-tri-n-butylstannyl derivatives, owing to their adequate compatibility with polymeric binders and other ingredients of the compositions.
According to the invention, there are also proposed compositions for antifouling coatings, containing, as the active component, one of said organotin compounds, a polymeric binder, a filler, a pigment, a solvent and various additives in the following ratio, in parts by weight:
______________________________________active component:______________________________________chlorinated organotin compound offormula (I) 5-10binder 7-30filler 25-30pigment 0.5-5.5additives 0-5.5solvent 10-35:______________________________________
The proposed composition may be of various types, depending on the active component used and other ingredients.
The preferable compositions in which the active component is compatible with the other ingredients are as follows:
______________________________________I. Composition with the following ratio of components,parts by weight:1. Chlorinated organotin compound of the formula (I),wherein R = n-C.sub.4 H.sub.9, R' = CH.sub.3, n = 1 10.02. Copolymer of vinyl chloride and vinylacetate 17.03. Colophony 12.04. Titanium white 28.05. Toluene 33.0.______________________________________II. Composition with the following ratio of compo-nents, parts by weight:1. Chlorinated organotin compound of the formula (I),wherein R = n-C.sub.4 H.sub.9, n = 0 10.02. Copolymer of vinyl chloride and vinylacetate 17.03. Colophony 12.04. Titanium white 28.05. Toluene 33.0.______________________________________III. Composition with the following ratio of compo-nents, parts by weight:1. Chlorinated organotin compound of the formula (I),wherein R = n-C.sub.4 H.sub.9, R' = CH.sub.3, n = 1 7.52. Postchlorinated polyvinyl chloride 8.03. Colophony 9.04. Zinc white 30.05. Dibutylphthalate 5.06. Salicylanilide 5.57. Ethylacetate and toluene in a 1:1 ratio 35.0.______________________________________IV. Composition with the following ratio of components,parts by weight:1. Chlorinated organotin compound of the formula (I),wherein R = C.sub.2 H.sub.5, R' = CH.sub.3, n = 1 10.02. Epoxy resin 30.03. Polyethylene polyamine 5.04. Dibutylphthalate 7.55. Zinc white 30.06. Toluene 12.5.______________________________________
The binders, fillers, pigments, solvents and other additives included in the proposed compositions are commercially available products.
The proposed compositions are produced by way of dispersing the respective components in a ball mill to a particle size of 60 to 70 microns. It takes 2 to 8 hours for the coatings to dry.
The above compositions for antifouling coatings, containing the proposed chlorinated organotin compounds of the above formula, exhibit superior performance characteristics such as antifouling activity, strength, adhesion and weatherproofness.
According to the invention, the method for producing compounds of the formula (I) comprises a condensation reaction of anhydrides of chlorinated polycyclic dicarboxylic acids of the formula (II) ##STR3## wherein R'=H, CH 3 and n=0,1, with hexaalkyldistannoxanes of the formula (III) R 3 SnOSnR 3 , wherein R is a lower alkyl, in the medium of an inert organic solvent. The reaction proceeds as follows: ##STR4## wherein R is a lower alkyl, R'=H,CH 3 and n=0,1.
The reaction is exothermic and occurs at room temperature, although at 60° to 80° C. it is more effective. The starting components may be taken in a stoichiometric ratio or with a slight excess of said anhydride. The resulting compounds are waxy or gummy products without any pungent odor and are readily soluble in organic solvents.
The starting components, i.e. anhydrides of chlorinated polycyclic dicarboxylic acids of the formula (II) and hexaalkyldistannoxanes of the formula (III) are well known and readily available compounds. The process for producing the composition can be easily implemented industrially.
Bearing in mind that the process for producing said compounds involves a single stage, can be conducted under mild conditions, does not require excessive power and additional reagent consumption, is simple and easy in implementation, and makes use of readily available starting components, the commercial value of the proposed compounds and antifouling compositions based thereon is obvious.
For a better understanding of the present invention specific examples of its practical embodiment are given by way of illustration, Examples 1 through 9 illustrating the obtaining of compounds and Examples 10 through 27, the obtaining of compositions on their basis.
EXAMPLE 1
Obtaining of bis-Trimethylstannyl Ester of 1,2,3,4,11,11-Hexachloro-6-methyltricyclo(4,2,1,0 5 ,10)undecene-2-dicarboxylic-7,8 Acid
A four-necked flask provided with a mechanical stirrer, a condenser, a thermometer, a dropping funnel and a nitrogen inlet tube is charged with 6.6 g (0.015 g.M) of anhydride of 1,2,3,4,11,11-hexachloro-6-methyltricyclo(4,2,1,0 5 ,10)undecene-2-dicarboxylic-7,8 acid and 200 ml of benzene. The mixture is stirred with heating at 60° C. till complete dissolution of the anhydride, then 3.4 g (0.01 g.M) of hexamethyldistannoxane dissolved in 10 ml of benzene are added into the reaction zone. The reaction is accompanied by heat evolution.
The reaction mixture is heated at 80° C. for 10 hours. The reaction product is isolated by extraction with heptane. Therewith, the excess amount of the unreacted anhydride precipitates, and the precipitate is separated by filtration. After distillation of the solvent and evacuation, the obtained product is dried in a vacuum desiccator at 40° C. 6.0 g (76% of the theoretical) of the product are obtained, with the following characteristics: melting point, 47.5° to 49° C.; molecular mass, 783.6 (determined by cryoscopy in benzene). Found, %: Cl 27.86, Sn 29.97. C 20 H 28 O 4 Cl 6 Sn 2 . Calculated, %; Cl 27.18, Sn 30.33.
IR spectra, cm -1 : ν C-Cl 680, ν s Sn-C 515, ν as Sn-C 610, ν C ═O 1790, 1830, 1595 (Me 3 SnOC--).
EXAMPLE 2
Obtaining of bis-Triethylstannyl Ester of 1,2,3,4,11,11-Hexachloro-6-methyltricyclo[4,2,1,0 5 ,10 ]undecene-2-dicarboxylic-7,8 Acid
Under conditions similar to those of Example 1, from 52.7 g (0.12 g.M) of the anhydride of Example 1 and 42.7 g (0.1 g.M) of hexaethyldistannoxane there are obtained 71.0 g (82% of the theoretical) of a yellowish syrupy product with η=612.5 cS, molecular mass of 865.8, and d 4 20 =1.4855. Found, %: Cl 24.75, Sn 27.26. C 26 H 40 O 4 Cl 6 Sn 2 . Calculated, %: Cl 24.54, Sn 27.39.
IR spectra, cm -1 : ν c-Cl 680, ν s Sn-C 505, ν as Sn-C 600, ν C ═O 1785, 1830, 1595 (Et 3 SnOOC--).
EXAMPLE 3
Obtaining of bis-Tri-n-propylstannyl Ester of 1,2,3,4,11,11-Hexachloro-6-methyltricyclo[4,2,1,0 5 ,10 ]undecene-2-dicarboxylic-7,8 Acid
Under conditions similar to those of Example 1, from 65.8 g (0.15. g.M) of the anhydride of Example 1 and 61.4 g (0.12 g.M) of hexa-n-propyldistannoxane there are obtained 97.5 g of the product in the form of a gummy light yellow mass. The yield is 85.5% of the theoretical, η=457 cS, molecular mass 950, d 4 20 =1.4220. Found, %: Cl 22.67, Sn 25.18. C 32 H 52 O 4 Cl 6 Sn 2 . Calculated, %: Cl 22.37, Cn 24.96.
Ir spectra, cm -1 : ν C-Cl 685, ν s Sn-C 490, ν as Sn-C 600, ν C ═O 1790, 1825, 1595 (n--Pr 3 SnOOC--).
EXAMPLE 4
Obtaining of bis-Tri-n-butylstannyl Ester of 1,2,3,4,11,11-Hexachloro-6-methyltricyclo[4,2,1,0 5 ,10 ]undecene-2-dicarboxylic-7,8 Acid
Under conditions similar to those of Example 1, from 43.9 g (0.1 g.M) of the anhydride of Example 1 and 65.6 g (0.11 g.M) of hexa-n-butyldistannoxane there are obtained 91.3 g of a viscous light yellow product. The yield is 88.2 of the theoretical, η=374.6 cS, d 4 20 =1.3689, molecular mass of 1,120. Found, %: Cl 20.85, Sn 23.24 C 38 H 64 O 4 Cl 6 Sn 2 . Calculated, %: Cl 20.55, Sn 22.93.
IR spectra, cm -1 ; ν C-Cl 60, ν s Sn-C 490, ν as Sn-C 600, ν C ═O 1790, 1820, 1590 (n--Bu 3 SnOOC--).
EXAMPLE 5
Obtaining of bis-Triethylstannyl Ester of 1,2,3,4,11,11-Hexachlorotricyclo-[4,2,1,0 5 ,10 ]undecene-2-dicarboxylic-7,8 Acid
Under conditions similar to those of Example 1, from 42.5 g (0.1 g.M) of anhydride of hexachlorotricycloundecene dicarboxylioacid and 42.7 g (0.1 g.M) of hexaethyldistannoxane there are obtained 65.4 g of a gummy light yellow product. The yield is 76.8% of the theoretical, η=680 cS, molecular mass of 850, d 4 20 =1.49.05. Found, %: Cl 25.41, Sn 26.34. C 25 H 38 O 4 Cl 6 Sn 2 . Calculated, %: Cl 24.97, Sn 27.83.
IR spectra, cm -1 : ν s Sn-C 510, ν as Sn-C 615, ν C-Cl 680, ν C ═O 1785, 1835, 1590 (Et 3 SnOOC--), ν C ═O 1600.
EXAMPLE 6
Obtaining of bis-Tri-n-butylstannyl Ester of 1,2,3,4,11,11-Hexachlorotoricyclo 4,2,1,0 5 ,10 undecene-2-dicarboxylic-7,8 Acid
Under conditions similar to those of Example 1, from 42.5 g (0.1 g.M) of the anhydride of Example 5 and 59.5 g (0.1 g.M) of hexa-n-butyldistannoxane there are obtained 84.2 g of a gummy transparent mass. The yield is 82.5%, η=390 cS, d 4 20 =1.3710, molecular mass of 1,015. Found, %: Cl 21.61, sn 22.95, C 39 H 62 O 4 Cl 6 Sn 2 . Calculated, %: Cl 21.09, Sn 23.50.
IR spectra, cm -1 : ν C-Cl 685, ν s Sn-C 495, ν as Sn-C 605, ν C ═O 1790, 1815, 1505 (n--Bu 3 SnOOC--).
EXAMPLE 7
Obtaining of bis-Triethylstannyl Ester of 1,2,3,4,7,7-Hexachlorobicyclo-[2,2,1]heptene-2-dicarboxylic-5,6 Acid
Under conditions similar to those of Example 1, from 44.5 g (0.12 g.M) of chlorendic anhydride and 42.7 g (0.1 g.M) of hexaethyldistannoxane there are obtained 71.4 g of a waxy light yellow product. The yield is 89.5%, melting point of 74.5° C., molecular mass of 800. Found, %: Cl 27.08, Sn 30.19, C 21 H 32 O 4 Cl 6 Sn 2 . Calculated, %: Cl 26.29, Sn 29.73.
IR spectra, cm -1 : ν C-Cl 680, ν s Sn-C 510, ν as Sn-C 610, ν C ═O 1780, 1840, 1595 (Et 3 SnOOC--).
EXAMPLE 8
Obtaining of bis-Tri-n-propylstannyl Ester of 1,2,3,4,7,7-Hexachlorolicyclo[2,2,1]-heptene-2-dicarboxylic-5,6 Acid
Under conditions similar to those of Example 1, from 44.5 g (0.12 g.M) of chlorendic anhydride and 51.1 g (0.1 g.M) of hexapropyldistannoxane there are obtained 79.4 g of a gummy product. The yield is 90%, η=810 cS, d 4 20 =1.4130, molecular mass of 885. Found, %: Cl 24.75, Sn 27.22. C 27 H 44 O 4 Cl 6 Sn 2 . Calculated, %: Cl 24.15, Sn 26.98.
IR spectra, cm -1 : ν C-Cl 675, ν s Sn-C 500, ν as Sn-C 600, ν C ═O 1770, 1840, 1590 (Pr 3 SnOOC--), ν C ═C 1600.
EXAMPLE 9
Obtaining of bis-Tri-n-butylstannyl Ester of Chlorendic Acid
Under conditions similar to those of Example 1, from 89 g (0.24 g.M) of chlorendic anhydride and 119 g (0.2 g.M) of hexan-butyldistannoxane there are obtained 178.7 g of a product in the form of a viscous resinous mass. The yield is 92.5%, η=720 cS, d 4 20 =1.3926, n D 20 =1.5281, molecular mass of 970. Found, %: Cl 21.86, Sn 25.11. C 33 H 56 O 4 Cl 6 Sn 2 . Calculated, %: Cl 22.05, Sn 24.56.
IR spectra, cm -1 : ν C-Cl 680, ν s Sn-C 490, ν as Sn-C 615, ν C ═O 1785, 1830, 1590 (n--Bu 3 SnOOC--).
The following examples illustrate compositions for antifouling coatings.
EXAMPLE 10
Composition containing a Compound of the Formula (I), Wherein R=n--C 4 H 9 , R'=CH 3 , n=1, Obtained As Described in Example 4
Charged into a ball mill are 10 parts by weight of said chlorinated organotin compound, 17.0 parts by weight of a copolymer of vinyl chloride and vinyl acetate, 12 parts by weight of colophony, 28 parts by weight of titanium white and 33 parts by weight of toluene. The charge is milled to a suspended particle size of 70 microns. The resulting composition is ready for use as antifouling coatings and can be applied by any conventional technique, such as spraying, application with a brush or a roller, etc. As a result, a uniform, durable matte coat 40 to 50 microns thick is formed. It takes 6 hours for the coating to dry. The properties of the coating are listed in Table 1.
EXAMPLE 11
Composition Containing a Compound of the Formula (I), Wherein R=n--C 4 H 9 , R'=H, n=1, Obtained As Described in Example 6
Under conditions similar to those of Example 10, there is prepared a composition with the following ratio of components, parts by weight:
______________________________________chlorinated organotin compound of the Formula (I),wherein R = n-C.sub.4 H.sub.9, R' = H, n = 1 10.0copolymer of vinyl chloride and vinyl acetate 17.0colophony 12.0titanium white 28.0toluene 33.0.______________________________________
The properties of the coating are listed in Table 1.
EXAMPLE 12.
Composition Containing a Compound of the Formula (I), Wherein R=n--C 4 H 9 , n=0, Obtained As Described in Example 9
Under conditions similar to those of Example 10, there is prepared a composition with the following ratio of components, parts by weight:
______________________________________chlorinated organotin compound of the formula (I),wherein R = n-C.sub.4 H.sub.9, n = 0 10.0copolymer of vinyl chloride and vinyl acetate 17.0colophony 12.0titanium white 28.0toluene 33.0.______________________________________
The properties of the coating are listed in Table 1.
EXAMPLE 13.
Composition Containing a Compound of the Formula (I), Wherein R=n--C 4 H 9 , R'=CH 3 , n=1, Obtained As Described in Example 4
Under conditions similar to those of Example 10, there is prepared a composition with the following ratio of components, parts by weight:
______________________________________chlorinated organotin compound of the formula (I),wherein R = n-C.sub.4 H.sub.9, R' = CH.sub.3, n = 1 7.5postchlorinated polyvinyl chloride 8.0colophony 9.0zinc white 30.0dibutylphthalate 5.0salicylanilide 5.5ethylacetate and toluene in a 1:1 ratio 35.0.______________________________________
The properties of the coating are listed in Table 1.
EXAMPLE 14.
Composition Containing a Compound of the Formula (I), Wherein R=n--C 4 H 9 , R'=H, n=1, Obtained As Described in Example 6
Under conditions similar to those of Example 19, there is prepared a composition with the following ratio of components, parts by weight:
______________________________________chlorinated organotin compound of the formula (I),wherein R = n-C.sub.4 H.sub.9, R' = H, n = 1 7.5postchlorinated polyvinyl chloride 8.0colophony 9.0Zinc white 30.0dibutylphthalate 5.0salicylanilide 5.5ethylacetate and toluene in a 1:1 ratio 35.0.______________________________________
The properties of the coating are listed in Table 1.
EXAMPLE 15.
Composition Containing a Compound of the Formula (I), Wherein R=n--C 4 H 9 , n=0, Obtained As Described in Example 9
Under conditions similar to those of Example 10, there is prepared a composition with the following ratio of components parts by weight:
______________________________________chlorinated organotin compound of the formula (I),wherein R = n-C.sub.4 H.sub.9, n = 0 7.5postchlorinated polyvinyl chloride 8.0colophony 9.0zinc white 30.0dibutylphthalate 5.0salicylanilide 5.5ethylacetate and toluene in a 1:1 ratio 35.0.______________________________________
The properties of the coating are listed in Table 1.
EXAMPLE 16.
Composition Containing a Compound of the Formula (I), Wherein R=n--C 4 H 9 , R'=CH 3 , n=1, Obtained As Described in Example 4
Under conditions similar to those of Example 10, there is prepared a composition with the following ratio of components, parts by weight:
______________________________________chlorinated organotin compound of the formula (I),wherein R = n-C.sub.4 H.sub.9, R' = CH.sub.3, n = 1 10.0epoxy resin 30.0polyethylene polyamine 5.0dibutylphthalate 7.5zinc white 30.0toluene 12.0.______________________________________
The properties of the coating are listed in Table 1.
EXAMPLE 17.
Composition Containing a Compound of the Formula (I), Wherein R=n--C 4 H 9 , n=0, Obtained As Described in Example 9
Under conditions similar to those of Example 10, there is prepared a composition with the following ratio of components, parts by weight:
______________________________________chlorinated organotin compound of the formula (I),wherein R = n-C.sub.4 H.sub.9, n = 0 10.0epoxy resin 30.0polyethylene polyamine 5.0dibutylphthalate 7.5zinc white 30.0toluene 12.5______________________________________
The properties of the coating are listed in Table 1.
EXAMPLE 18.
Composition Containing a Compound of the Formula (I), Wherein R=CH 3 , R'=CH 3 , n=1, Obtained As Described in Example 1
Under conditions similar to those of Example 10, there is prepared a composition with the following ratio of components, parts by weight:
______________________________________chlorinated organotin compound of the formula (I),wherein R = CH.sub.3, R' = CH.sub.3, n = 1 10.0epoxy resin 30.0polyethylene polyamine 5.0dibutylphthalate 7.5zinc white 30.0toluene 12.5______________________________________
The properties of the coating are as follows: impact strength, 70 kg/cm; bending strength, 1 mm; pendulum hardness, 0.35; Weathering stability, 8 points; duration of antifouling action, 18 months.
EXAMPLE 19.
Composition Containing a Compound of the Formula (I), Wherein R=C 2 H 5 , R'=CH 3 , n=1, Obtained As Described in Example 2
Under conditions similar to those of Example 10, there is prepared a composition with the following ratio of components, parts by weight:
______________________________________chlorinated organotin compound of the formula (I),wherein R = C.sub.2 H.sub.5, R' = CH.sub.3, n = 1 10.0epoxy resin 30.0polyethylene polyamine 5.0dibutylphthalate 7.5zinc white 30.0toluene 12.5.______________________________________
The properties of the coating are as follows: impact strength, 75 kg/cm; bending strength, 1 mm; hardness, 0.25; weathering stability, 7 points; duration of antifouling action, 20 months.
EXAMPLE 20.
Composition Containing a Compound of the Formula (I), Wherein R=n--C 3 H 7 , R'=CH 3 , n=1, Obtained As Described in Example 3
Under conditions similar to those of Example 10, there is prepared a composition with the following ratio of components, parts by weight:
______________________________________chlorinated organotin compound of the formula (I),wherein R = n-C.sub.3 H.sub.7, R' = CH.sub.3, n = 1 10.0epoxy resin 30.0polyethylene polyamine 5.0dibutylphthalate 7.5zinc white 30.0toluene 12.5.______________________________________
The properties of the coating are as follows: impact strength, 80 kg/cm; bending strength, 1 mm; hardness, 0.3; weathering stability, 8 points; duration of antifouling action, 20 months.
EXAMPLE 21.
Composition Containing a Compound of the Formula (I), Wherein R=C 2 H 5 , R'=H, n=1, Obtained As Described in Example 5
Under conditions similar to those of Example 10, there is prepared a composition with the following ratio of components, parts by weight:
______________________________________chlorinated organotin compound of the formula (I),wherein R = C.sub.2 H.sub.5, R' = H, n = 1 10.0epoxy resin 30.0polyethylene polyamine 5.0dibutylphthalate 7.5zinc white 30.0toluene 12.5.______________________________________
The properties of the coatings are as follows: impact strength, 65 kg/cm; bending strength, 1 mm; hardness, 0.18; weathering stability, 7 points; duration of antifouling action, 18 months.
EXAMPLE 22.
Composition Containing a Compound of the Formula (I), Wherein R=C 2 H 5 , n=0, Obtained As Described in Example 7
Under conditions similar to those of Example 10, there is prepared a composition with the following ratio of components, parts by weight:
______________________________________chlorinated organotin compound of the formula (I),wherein R = C.sub.2 H.sub.5, n = 0 10.0epoxy resin 30.0polyethylene polyamine 5.0dibutylphthalate 7.5zinc white 30.0toluene 12.5.______________________________________
The properties of the coating are as follows: impact strength, 80 kg/cm; bending strength, 1 mm; hardness, 0.15; weathering stability, 7 points; duration of antifouling action, 20 months.
EXAMPLE 23.
Composition Containing a Compound of the Formula (I), Wherein R=C 3 H 7 , n=0, Obtained As Described in Example 8
Under conditions similar to those of Example 10, there is prepared a composition with the following ratio of components, parts by weight:
______________________________________chlorinated organotin compound of the formula (I),wherein R = C.sub.3 H.sub.7, n = 0 10.0epoxy resin 30.0polyethylene polyamine 5.0dibutylphtalate 7.5zinc white 30.0toluene 12.5______________________________________
The properties of the coating are as follows: impact strength, 70 kg/cm; bending strength, 1 mm; hardness, 0.25; weathering stability, 8 points; duration of antifouling action, 20 months.
EXAMPLE 24.
Composition Containing a Compound of the Formula (I), Wherein R=C 2 H 5 , R'=CH 3 , n=1, Obtained As Described in Example 2
Under conditions similar to those of Example 10, there is prepared a composition with the following ratio of components, parts by weight:
______________________________________chlorinated organotin compound of the formula (I),wherein R = C.sub.2 H.sub.5, R' = CH.sub.3, n = 1 7.5postchlorinated polyvinyl chloride 8.0colophony 9.0zinc white 30.0dibutylphthalate 5.0salicylanilide 5.5ethylacetate and toluene in a 1:1 ratio 35.0.______________________________________
The properties of the coating are as follows: impact strength, 50 kg/cm; bending strength, 1 mm; hardness, 0.15; weathering stability, 7 points; duration of antifouling action, 18 months.
EXAMPLE 25.
Composition Containing a Compound of the Formula (I), Wherein R=C 2 H 5 , n=0, Obtained As Described in Example 7
Under conditions similar to those of Example 10, there is prepared a composition with the following ratio of components, parts by weight:
______________________________________chlorinated organotin compound of the formula (I),wherein R = C.sub.2 H.sub.5, n = 0 7.5postchlorinated polyvinyl chloride 8.0colophony 9.0zinc white 30.0dibutylphthalate 5.0salicylanilide 5.5acetone and toluene in a 1:1 ratio 35.0.______________________________________
The properties of the coating are as follows: impact strength, 55 kg/cm; bending strength, 1 mm; hardness, 0.16; weathering stability, 7 points; duration of antifouling action, 22 months.
EXAMPLE 26.
Composition Containing a Compound of the Formula (I), Wherein R=C 2 H 5 , n=0, Obtained As Described in Example 7
Under conditions similar to those of Example 10, there is prepared a composition with the following ratio of components, parts by weight:
______________________________________chlorinated organotin compound of the formula (I),wherein R = C.sub.2 H.sub.5, n = 0 10.0copolymer of vinyl chloride and vinyl acetate 17.0colophony 12.0titanium white 28.0toluene 33.0.______________________________________
The properties of the coating are as follows: impact strength, 50 kg/cm; bending strength, 1 mm; hardness, 0.2; weathering stability, 8 points; duration of antifouling action, 24 months.
EXAMPLE 27.
Composition Containing a Compound of the Formula (I), Wherein R=C 2 H 5 , R'=CH 3 , n=1, Obtained As Described in Example 2
Under conditions similar to those of Example 10, there is prepared a composition with the following ratio of components, parts by weight:
______________________________________chlorinated organotin compound of the formula (I),wherein R = C.sub.2 H.sub.5, R' = CH.sub.3, n = 1 7.5postchlorinated polyvinyl chloride 8.0colophony 9.0zinc white 30.0dibutylphthalate 5.0salicylanilide 5.5acetone and toluene in a 1:1 ratio 35.0.______________________________________
The properties of the coating are as follows: impact strength, 55 kg/cm; bending strength, 1 mm; hardness, 0.15; weathering stability, 7 points; duration of antifouling action, 18 months.
The properties of coatings from the compositions described in Examples 10 through 17 are listed in Table 1. For comparison, there are also given data for a prior art composition with active component (C 4 H 9 ) 3 SnOSn(C 4 H 9 ) 3 . As can be seen from Table 1, coatings from the proposed compositions exhibit sufficiently high performance characteristics.
Coatings containing the proposed chlorinated organotin compounds, applied on steel and aluminum plates 40×60 cm in size have been tested in sea water under natural conditions, in a region of intensive fouling, at a depth of 4 to 5 m.
The test results are summarized in Table 2.
TABLE 1__________________________________________________________________________Properties of Antifouling Coatings Based on Various Compositions Prior art coatingProperties of Compositions for antifouling coatings as per ExamplesCoatings 10 11 12 13 14 15 16 17 (C.sub.4 H.sub.9).sub.3 SnOSn(C.sub .4 H.sub.9).sub.3__________________________________________________________________________1. Impact strength, kg/cm 50 50 55 50 55 55 70 70 502. Bending strength, mm 1 1 1 1 1 1 1 1 23. Hardness, kg/sq.mm 0.15 0.15 0.17 0.16 0.18 0.25 0.15 0.25 0.354. Cross-cut adhesion 1 1 1 1 1 1 0.0 0.0 25. Particle size, microns 70 60 65 70 70 70 70 65 506. Weathering stability,points 7 7 7 8 7 8 8 8 27. Duration of antifoul-ing action, months 18 18 22 18 20 24 20 18 128. Drying time, hrs 6 7 8 2 3 2 2 2 8__________________________________________________________________________
TABLE 2__________________________________________________________________________Antifouling Activity of Chlorinated OrganotinCompounds of the General Formula (I) Degree of fouling, kg/sq.m Leaching rate, Test duration, monthsR R' n mg/sq.cm per day 6 12 18 24 Note__________________________________________________________________________CH.sub.3 CH.sub.3 I 0.067 0.0II 0.018 0.115 0.215 On test specimens withoutC.sub.2 H.sub.5 CH.sub.3 I 0.051 0.009 0.015 0.095 0.155 coating, a large amountC.sub.2 H.sub.5 H I 0.049 0.009 0.016 0.105 0.165 of biomass, 10 to 15 kg/sqC.sub.2 H.sub.5 -- 0 0.031 0.0I 0.105 0.165 0.205 m over 6 to 8 months,n-C.sub.3 H.sub.7 CH.sub.3 I 0.038 0.008 0.014 0.095 0.18 has been accumulated.n-C.sub.4 H.sub.9 CH.sub.3 I 0.027 0.005 0.09 0.II 0.145n-C.sub.4 H.sub.9 H I 0.025 0.005 0.08 0.12 0.135n-C.sub.4 H.sub.9 -- 0 0.028 0.003 0.06 0.095 0.125(C.sub.4 H.sub.9).sub.3 SnOSn(C.sub.4 H.sub.9).sub.3 0.68 0.125 0.75 1.15 1.86(prior art)__________________________________________________________________________ | Proposed herein are bis-trialkylstannyl derivatives of chlorinated polycyclic dicarboxylic acids, of the general formula ##STR1## wherein R is a lower alkyl, R'=H,CH 3 , n=0,1, which are obtained by a condensation reaction of anhydrides of the respective dicarboxylic acids with hexaalkyldistannoxanes R 3 SnOSnR 3 , wherein R is a lower alkyl, in the medium of an organic solvent.
The resulting compounds exhibit antifouling activity and represent active components of coatings intended to protect ships' bottoms and the submerged parts of various hydraulic structures against fouling. Antifouling polymer coatings containing said compounds are more effective and durable, and over five and more years prevent biomasses of marine organisms of vegetal and animal origin from accumulating on the surface. | 2 |
BACKGROUND OF THE INVENTION
The present invention relates to super-regenerative receivers in garage door openers or "operators". More specifically, the present invention relates to a cascode preamplification circuit stage for a super-regenerative circuit, a RF receiver equipped with such a cascode preamplifier stage in combination with a super-regenerative circuit, and a garage door opener including a such receiver.
Electrical garage door openers include radio frequency (RF) receivers to receive control signals from a remote RF transmitter, namely a hand-held transmitter typically kept within the homeowner's car. A type of radio receiver, hereinafter referred to as a super-regenerative receiver, is, from a cost standpoint, very attractive for use in garage door openers. The cost of manufacture for such receivers may be about half of that for crystal oscillator-based receivers. However, without expensive shielding, super-regenerative receivers are electrically noisy.
U.S. Pat. No. 3,746,999 discusses examples of the electrical noise that is attributed to this type of receiver. This patent comments on noise resulting from the generation of quench oscillations that are developed to release and inhibit a regenerative circuit, and goes on to set forth problems that arise as a result of the quench oscillations such as interaction with local oscillations in the proximity of the receiver. Other examples of noise problems in super-regenerative receivers are radiation of the superimposed tuning and quench frequencies, and also other unwanted emission at different frequencies.
In garage door openers, interaction between conventional super-regenerative receivers becomes very problematic where two or more such openers are employed in close proximity, for example at the same site. Typically, garage door opener receivers are manufactured to operate at the same frequency. Thus, where multiple such operators are employed at the same site, it is not unlikely that one receiver will lock on to the quench oscillations of another receiver and then ignore the radio frequency signal from its associated hand-held transmitter. As such, the receiver locked onto the quench oscillation will not respond to operator commands issued by way of the hand-held transmitter. At minimum, such conditions limit the effective range of the hand-held transmitter from the receiver. At worst, they result in a lock-up or non-responsiveness by one or more receiver.
SUMMARY OF THE INVENTION
The present invention pertains to a cascode preamplifier stage for a super-regenerative circuit, a super-regenerative apparatus including such a preamplifier stage in combination with a RF super-regenerative circuit, a super-regenerative receiver equipped with such a super-regenerative circuit apparatus, and a garage door opener including such a super-regenerative receiver. This results in a reliable garage door operator that has high sensitivity with low noise and features very low unwanted RF output radiation. The super-regenerative receiver, according to the present invention, overcomes interference problems in conventional super-regenerative receiver based door operators due to oscillation radiation when plural conventional door operators are installed at close proximity. The present invention accomplishes this goal without significantly increasing the cost of the super-regenerative receiver, thus providing a receiver that is attractive for use in a garage door operator, to minimize the cost of the operator.
The present invention relies upon a cascode preamplifier stage that cooperates with a regenerative circuit stage to minimize the amount of RF radiation emitted by a receiver that includes these stages. At the same time, the preamplifier stage increases sensitivity for the super-regenerative circuit. The preferred cascode preamplifier stage has low noise, forward gain characteristics and also very high reverse isolation. It has a low input impedance at its coupling with the super-regenerative circuit stage to highly couple these stages and reduce noise transferred therebetween. The preferred cascode preamplifier stage itself features a cascade dual-gate field effect transistor (FET) and bipolar transistor arrangement that is resistively loaded to ensure stable amplification. Preferably, the FET and bipolar arrangement also includes a phase shifting arrangement, to phase shift an antenna signal carried forward to further enhance stability while protecting the resultant receiver and door operator from generating unintended oscillation. More preferably, the resistive loading device cooperates with the phase shifter to enhance phase shift within the preamplifier stage.
Briefly, a radio frequency (RF) controlled door operator responsive to RF signals from an associated remote RF transmitter in accordance with the present invention comprises: a motor for opening and closing a door; a super-regenerative receiver for recovering a data signal from a received RF signal, the receiver including a super-regenerative circuit with an input and an output; a cascode preamplifier stage connected to the input of the super-regenerative circuit for amplifying a received RF signal to provide an amplified signal and applying its amplified signal to the super-regenerative circuit, the preamplifier stage including a field effect transistor (FET) and a bipolar transistor connecting the FET to the super-regenerative circuit, the FET and the bipolar transistor cooperating to produce low gain in a direction from the input of the super-regenerative circuit to an input of the preamplifier stage, data amplifier means having an input connected to the output of the super-regenerative circuit for recovering a data signal from an output signal from the super-regenerative receiver circuit, and decoder means connected to the data amplifier means for decoding a data signal applied thereto by the data amplifier means and generating a decoded control signal therefrom; and control means, responsive to a decoded control signal from the decoder means, for controlling the motor.
BRIEF DESCRIPTION OF THE DRAWINGS
Further aspects and features of the present invention will be even more apparent from the following detailed description and drawings, and the appended claims. In the drawings:
FIG. 1 is a block diagram showing a preferred garage door operator in accordance with the present invention;
FIG. 2 is a circuit diagram showing details of the cascode preamplifier stage of the garage door operator of FIG. 1;
FIG. 3A is a Smith diagram illustrating input impedance characteristics looking through the cascode preamplifier stage of FIG. 2 from the antenna of the door operator of FIG. 1 to the output of the preamplifier stage;
FIG. 3B is a diagram, similar to FIG. 3A, showing the impedance characteristics looking backwardly through the cascode preamplifier from the output thereof back to the antenna;
FIG. 4A is a linear frequency plot showing the forward gain through the cascode preamplifier stage of FIG. 2 with particular focus at the tuning frequency of the preferred super-regenerative circuit of FIG. 5;
FIG. 4B is a plot similar to FIG. 4A of the reverse gain or isolation of the cascode preamplifier stage of FIG. 2;
FIG. 5 is a schematic diagram showing the preferred super-regenerative circuit ideally suitable for use in the garage door operator of FIG. 1;
FIG. 6 is a logarithmic amplitude plot of radiation output of the super-regenerative receiver of FIG. 5 when fed by the cascode preamplifier stage of FIG. 2;
FIG. 7 is a circuit diagram of a five-pole bandpass filter suitable for use in the garage door operator and super-regenerative circuit apparatus in accordance with the present invention; and
FIG. 8 is a circuit diagram of a RC filter stage and a data amplifier stage suitable for use with the garage door operator and super-regenerative circuit apparatus in accordance with the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIG. 1 shows a garage door operator 10 equipped with a cascode preamplifier, in a super-regenerative receiver, in accordance with the present invention. Door operator 10 is shown in block diagram form. Herein, particular attention will be given to the super-regenerative receiver 12 which detects and decodes control signals that are applied by the receiver to a control system 14 which controls a motor 16 to open and close a garage door, gate, or like assembly 18.
Preferred super-regenerative receiver 12 is contemplated to receive at a 390 Mhz carrier frequency and is tuned thereto. It detects a single frequency (390 Mhz), continuous wave (CW) signal that is on-and-off modulated to superimpose a data signal on the 390 MHz carrier wave to produce a RF command signal. The quench frequency of receiver 12 is about 1 Mhz.
Preferred receiver 12 is coupled to an antenna 20 that is connected to a band pass filter 22 in the receiver. Output from the band pass filter 22 is applied as input to the cascode preamplifier stage 24. Output from the cascode preamplifier 24 is coupled to a super-regenerative circuit 26 that includes a quench oscillator 28. Super-regenerative circuit 26 retrieves the RF command signal and applies the retrieved command signal, with the quench signal also superimposed thereon, as low level input to a RC filter 30. In the preferred form of receiver 12, and door operator 10, filter 30 cooperates with a data amplifier 32 which together filter both the carrier frequency and the quench frequency, amplify and further process the filtered signal to recover the data signal prior to providing the data signal to a decoder 34. Decoder 34 receives the amplified data signal as input, decodes it, and supplies decoded control signals to the controller 14 which controls motor 16 and the door equipment 18 accordingly.
FIG. 2 is a circuit diagram of cascode preamplifier stage 24. The heart of cascode preamplifier 24 is a dual gate FET Q1 and a bipolar transistor Q2. A 33 nH inductor L1 connects the drain D of FET Q1 to the emitter leg E of bipolar transistor Q2. Inductor L1 provides phase adjustment for the cascade connection of FET Q1 and bipolar transistor Q2.
Cascode preamplifier stage 24 receives filtered RF command signal input from antenna 20 through a 1.2 pF capacitor Cl located at the output of band pass filter 22 and the input of the cascode preamplifier. Capacitor C1 is transparent to RF input from filter 22 but blocks DC voltage therefrom. The RF command signal passed by capacitor C1 is applied to gate G1 of FET Q1. A voltage divider formed by a 470K resistor R1 and a 22k resistor R10 provides DC bias for gate G1 at about 0.5 VDC. A 3.9 pF capacitor C2 and a 33 pF capacitor C3 short AC voltage over R1 to ground prior to contact with the power supply.
The other gate of FET Q1, namely gate G2, receives a DC bias voltage of about 2.7 VDC by way of its connection to a DC gain set control circuit 100. Circuit 100 connects to supply power through capacitor C2 and a 75K resistor R2. Circuit 100 includes the parallel arrangement of a 22K resistor R3, a 3.9 pF capacitor C4 and a 33 pF capacitor C5, all connected between a line to gate G2 and ground. The circuit 100 including resistor R3, capacitor C4, and capacitor C5 strips AC components from the DC bias voltage applied to gate G2.
Next, note the source S of FET Q1. Source S is connected to a DC feedback and stability network 110. In preferred cascode stage 24, network 110 consists of a 10 Ω resistor R4 and a 33 pF C5 connected in parallel between the source S and ground.
Preferred cascode preamplifier 24 includes a resistive loading network 120 connected in parallel with inductor L1 to the emitter E of transistor Q2 at a connection point P1. Network 120 includes a series connection of a 200 Ω resistor R5, from connective point P1, and a 33 pF capacitor C6 connected between resistor R5 and ground. Network 120 stabilizes the cascading connection of FET Q1 and transistor Q2. It also reduces the intensity of the 390 MHz spectrum emitted by receiver 12. Network 120 further cooperates with inductor L1 to phase shift the RF command signal forward. Likewise, inductor L1 further contributes to stability provided primarily by network 120. Given this disclosure, those of ordinary skill in the art also will note that in some applications, a 0.5 pF capacitor, connected to inductor L1 (prior to connection point P1) and to ground can be used.
With particular focus now on bipolar transistor Q2, the base B of transistor Q2 is supplied with DC bias by bias circuit 130. Power supply voltage is applied to the base of transistor Q2 through a 5.6K resistor R6 and thereafter a network of an 11K resistor R7, in parallel with a 10 Ω resistor R8, and a 33 pF capacitor C7 in series with R8. Bias circuit 130 applies a DC bias of about 6.7 VDC to the base B of transistor Q2.
Another gain network 140, that also contributes to stability in preamplifier 24, is connected to the collector C of transistor Q2, upstream of the output of cascode preamplifier stage 24. Network 140 is seen to include a parallel connection of a 200 Ω resistor R9 and a 0.01 μF capacitor C8. In gain network 140, resistor R9 has a lower value than is normally found in such an arrangement. At its output, cascode preamplifier 24 includes a 33 pF coupling capacitor C9. Capacitor C9 likewise is transparent to RF but blocks DC voltage. As such, coupling capacitor C9 prevents noise and DC from being applied to the super-regenerative circuit 26 connected to the preamplifier output.
In preferred cascode stage 24, FET Q1 acts as a low noise amplifier. The FET Q1 has low reverse gain, i.e. high isolation from the output of preamplifier stage 24, at capacitor C9, to the input thereof at capacitor C1. Such low noise and high isolation characteristics act to limit oscillation that otherwise would be radiated by receiver 12. Bipolar transistor Q2, arranged in common base configuration, further increases the isolation attributes of FET Q1. The parallel connection of inductor L1, and network 120 consisting of resistor R5 and capacitor C6 both add to the stability of the resulting super-regenerative receiver 12 by resistive loading, and provide for phase adjustment. Resistor R5 and capacitor C6 primarily provide the resistive loading that increases stability and decreases emission of 390 MHz oscillation. Inductor L1 primarily advances the phase of the RF signal but resistor R5 and capacitor C6 also contribute to phase control. In the configuration of preferred preamplifier stage 24, bipolar transistor Q2, in addition to providing further isolation, also contributes to lowering the noise factor for the super-regenerative circuit by providing gain. Resistor R9, by virtue of its low value, further contributes to the stability of the receiver. These components, in cooperation with the high value of output capacitor C9, heavily couple preamplifier stage 24 to super-regenerative circuit stage 26 to reduce noise within the receiver 12.
Reference now is made to FIGS. 3A through 4B. FIG. 3A is a Smith chart showing the impedance characteristics of a commercial form of cascode preamplifier stage 24 as seen from the antenna terminal. As apparent from FIG. 3A, the impedance, z f , as seen from the antenna terminal generally is given by z f =(61-j91). On the other hand, FIG. 3B shows the impedance characteristics of the same commercial embodiment of preamplifier 24 looking upstream of the amplifier from its output at coupling capacitor C9. The impedance, z r , shown by the Smith chart of FIG. 3B generally is given by z r =(6-j72). As appreciated by those of ordinary skill in the art, these impedance measurements may differ. FIG. 4A and FIG. 4B illustrate the forward and reverse gain respectively through the commercial form of preferred cascode preamplifier 24. As seen from FIG. 4A, the forward gain at 390 MHz is about 9.7 db. As seen from FIG. 4B, the reverse gain or isolation of cascode preamplifier 24 at 390 MHz is about -43.97 db.
From the disclosure hereof, alternative configurations will become apparent to those of ordinary skill in the art. For instance, a DC block by means of a drain load resistor, or an inductor for drain bias, could be provided between FET Q1 and bipolar transistor Q2. Further, if it were desired to remove the ground plane from the circuit board on which preamplifier 24 is mounted, a parallel capacitor could be placed across inductor L1, to compensate for the ground plane removal. Also, an inductor or a transformer could be used to bias bipolar transistor Q2. Further, somewhat lower capacitance values for capacitor C9 also could be acceptable. The range of capacitance values for capacitor C9 could be from about 10 pF to about 50 pF and still maintain high coupling between the preamplifier 24 and the super-regenerative circuit 26.
Next, consideration is made of the super-regenerative circuit 26 and its accompanying quench voltage oscillator 28. Super-regenerative circuit 26 can be conventional. However, a preferred form of a super-regenerative circuit is disclosed herein and is ideally suited for use in preferred receiver 12 because of its tight coupling and cooperation with cascode preamplifier stage 24. Such preferred super-regenerative circuit 26 and quench voltage oscillator 28 are shown at the component level in FIG. 5. The super-regenerative circuit and quench oscillator of FIG. 5, when used in connection with preferred cascode preamplifier stage 24, display the reduced oscillation radiation output level such as shown in FIG. 6.
Preferred super-regenerative circuit 26 connects to coupling capacitor C9 through a voltage divider 200. Voltage divider 200 includes a 24K resistor R20 and a 4.7K resistor R22. Resistor R20 also is connected in parallel with a 100 pF bypass capacitor C20. A connective point P20 connects voltage divider 200, bypass capacitor C20, and the quench oscillator 28 to the base of bipolar transistor Q20.
As stated, preferred quench oscillator 28 oscillates at about 1 MHz, which oscillation primarily is set by the 220 nH inductor L20 connected between the base and the emitter of transistor Q20. One terminal of inductor L20 is connected to the emitter of transistor Q20. The other terminal of inductor L20 is connected to a voltage divider 210 provided by 300 Ω resistor R23 and a 470 Ω resistor R24. A 220 pF capacitor C22 connects resistor R22 to the connective point P20 and thus to the base of transistor Q20.
Capacitor C22, resistors R23, R24, and inductor L20 determine the quench frequency of oscillator 28. Values of capacitor C22, resistors R23, R24, and inductor L20 are selected to lower the noise figure of receiver 12, and to tune the frequency where receiver is sensitive to be close to the null in its radiated spectrum.
Bypass capacitor C20, a 1 pF capacitor C24, and an inductor L22 tune super-regenerative circuit 26 for operation at 390 MHz. In a preferred form of super-regenerative circuit 26, inductor L22 can have a value within a range of about 52 nH to about 63 nH. In practice, as will be appreciated by those of ordinary skill in the art, the tuned or operation frequency of circuit 26 will be set by the inductor L22, the stray capacitance thereof, and the collector capacitance of transistor Q20. Capacitor C24 arranges transistor Q20 in common base configuration.
A small signal recovery network 220 connects between a terminal of inductor L22 and bypass capacitor C20. Network 220 includes a 22 μF filtering capacitor C26 to decouple the quench oscillations from the system power supply. Resistor R26, connected in parallel with capacitor C26, is a 4.7K load resistor. A 33 pF capacitor C28 is connected to the other side of resistor R26 and shorts RF to ground. Signal recovery is developed over an 18K recovery resistor R28, from which the recovered RF command signal, together with the quench oscillation, are output on the 3.6K output resistor R30. The other side of output resistor R30 connects to the input of the RC filter 30 for the regenerative circuit 26.
FIG. 7 shows a preferred form of a bandpass filter 22' suitable for use as filter 22 in the present invention. As seen from FIG. 7, preferred bandpass filter 22' includes a 1.5 pF capacitor C40 located between the antenna 20 and a first inductor L40. Inductor L40 can be in the range of about 68 nH to about 86 nH. It, in turn, is connected to a second inductor L42, which in turn connects to the input capacitor C1 of cascode preamplifier stage 24. Inductor L42 can have a value in the range of about 88 nH to about 110 nH. Connected in parallel between inductors L40 and L42 is a parallel network provided by a 12 pF capacitor C42 and a 3.3 pF capacitor C44, connected between the inductors L40 and L42 and ground. Capacitor C40, inductor L40, capacitor C42, capacitor C44, inductor L42, and also capacitor C1, provide a five-pole bandpass filter and impedance matching network for receiver 12. Preferred filter 22' transforms the impedance of antenna 20 to provide low noise matching with the FET Q1 of preamplifier stage 24. This provides suitable protection to the receiver 12 from signals outside of the receivers' band width. Alternatively, as also will be appreciated by those of ordinary skill in the art, different bandpass filter arrangements, with, for example, a lesser number of poles, could be substituted for filter 22' without detracting from the operation of the present invention.
A preferred version of RC filter 30 and data signal amplifier 32 is shown in FIG. 8 and labelled as filter 30' and data signal amplifier 32' respectively. As seen from FIG. 8, resistor R30 at the output of super-regenerative circuit 26 also forms part of the RC filter 30'. Filter 30' includes resistor R30, a 2.2K resistor R50 connected to resistor R30, and a 100 pF capacitor C50 connected in parallel therebetween. On the other side of resistor R50, a 0.0068 μF capacitor C52 connects between resistor R50 and ground. Resistor R30, capacitor C50, and resistor R50 cooperate to filter the carrier frequency component from the low level superimposed RF command and quench signals recovered by resistor R28 of super-regenerative circuit 26. Resistor R50 and capacitor C52 filter the quench oscillation to provide a filtered signal.
Preferred data amplifier 32' includes a first substage 60 defined by operational amplifier 62, and a second substage 70 including a bipolar transistor Q70 and a second operational amplifier 72. The first substage 60 squares the filtered signal applied to it from the RC filter 30' by provision of a longer time constant on the non-inverting input to operational amplifier 62. In the second substage 70, transistor Q70 further amplifies the squared signal. The open loop configuration of the second substage 70, including operational amplifier 72, further shapes the squared signal byway of the time constant difference between the inputs of amplifier 72. As also seen from FIG. 8, substage 60 includes several other discreet components, namely resistors R60, R62, R64, R66, and capacitors C60, C62 and C64 that are not discussed in detail herein. The values of the components, however, are given in FIG. 8. The same is done for substage 70 and its discreet components R70, R72, R74, R76, and R78, and capacitor C70.
As noted in the foregoing, FIGS. 7 and 8 merely show well suited filter and data amplifier arrangements for use in connection with the present invention. However, as will be apparent to those of ordinary skill in the art, other alternatives to these arrangements can be provided.
The operation of preferred receiver 12 now will be described with reference to preamplifier 24 and the other preferred elements discussed hereinbefore. Five pole bandpass filter 22' filters noise and other out-of-band signals to apply a received 390 MHz, CW modulated command signal to preamplifier stage 24 from antenna 20. Filter 22' is configured to provide a good impedance match to FET Q1 of preamplifier 24.
Preamplifier stage transistors Q1 and Q2 provide low-noise amplification of the filtered signal from filter 22' prior to coupling the signal to super-regenerative circuit 26. This permits a high degree of signal transfer to the super-regenerative stage 26 without dampening oscillation in the super-regenerative stage. While preamplifier stage 24 has high gain in the forward direction, FET Q1 and the common base configuration of transistor Q2 ensure very low gain or high isolation in the reverse direction from output to input. Transistors Q1 and Q2 and their associated resistive loading network 120 and phase shifting elements (inductor L1 and network 120) thus decouple super-regenerative circuit 26 and quench oscillator 28 from antenna 20, in the reverse direction, to limit the receiver's radiation at 390 MHz, and to prevent other undesired oscillation in the receiver. Specifically, resistive loading by resistor R5 and capacitor C6 contribute to reducing emission of the receiver's 390 MHz spectrum as well as lending stability to the combination of stages 24 and 26.
Capacitor C9 heavily couples an amplified (filtered) output signal to super-regenerative circuit 26. The high coupling factor improves the noise factor in receiver 12. When the output signal from cascode preamplifier stage 24 is coupled to super-regenerative circuit 26, the amplified signal alters the quench oscillation period and amplitude. This alters the collector current of transistor Q20 and creates gain in the super-regenerative circuit stage 26. Circuit 26 develops a modified command signal including the command signal with the quench oscillation superimposed thereon as a recovered signal across resistor R28, and couples the recovered signal to the filter 30' and data amplifier 32' stages over resistor R30. The recovered signal, as applied to filter 30', is present on capacitor C50. The recovered signal has a very low intensity level. In filter 30', resistor R30, capacitor C50 and resistor R50 filter the carrier frequency component from the recovered signal to provide a filtered recovered signal, still superimposed with the quench signal. Resistor R50 also forms the next filtering substage with capacitor C52 to filter the quench frequency from the filtered recovered signal. From here, operational amplifier 62 squares and level shifts the fully filtered signal to apply a level shifted signal to transistor Q7 which in turn provides for further amplification thereof. Transistor Q7 applies the amplified, level-shifted signal to operational amplifier 72 which shapes the level shifted signal, to provide the data signal as its output. Decoder 34 receives the recovered data signal from preferred data amplifier 32', decodes it and accordingly applies decoded control signals to controller 14.
The present disclosure includes subject matter defined in the appended claims, as well as that of the foregoing description and drawings. Although the present invention has been described in connection with preferred forms thereof, and therefore with a certain degree of particularity, it is to be understood that the present disclosure of the preferred forms is made only by way of example and that numerous changes in the details of construction, beyond those expressly described herein, may be made, and that changes in the combination and arrangement of parts may be made without departing from the spirit and the scope of the invention as hereinafter claimed. | A door operator includes a low noise, low radiation emission but high sensitivity super-regenerative receiver. The low radiation emission of the receiver allows the installation of plural operators in close proximity. The door operator receiver includes a super-regenerative circuit apparatus with a super-regenerative circuit and a resistively loaded cascode preamplifier stage that phase shifts a received RF signal and tightly couples the preamplifier stage output to the super-regenerative circuit. A cascode circuit arrangement of a field effect transistor (FET) and a bipolar transistor provides forward gain and very high reverse direction gain or isolation for the preamplifier stage. Preferably, the resistive loading elements and the phase-shifting elements are coupled to the cascode circuit between the transistors. The present invention also relates to a cascode preamplifier stage, a super-regenerative circuit, and a RF receiver each including such a preamplifier stage. | 7 |
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] Embodiments of the present invention generally relate to the field of fluid extraction from bore holes. More particularly the present invention relates to artificial lifting devices and methodologies for retrieving fluids, such as crude oil, from bores where the fluid does not have sufficient hydrostatic pressure to rise to the surface of the earth of its own accord. More particularly still, the present invention relates to the field of recovery of such fluids, where the fluid temperature of the fluids in the well bore exceeds the temperature at which the sealing materials in the pump rapidly deteriorate, to the point of failure.
[0003] 2. Description of the Related Art
[0004] The recovery of fluids such as oil and other hydrocarbons from bore holes, where the fluid pressure in the bore hole is insufficient to cause the fluid to naturally rise to the earths' surface, is typically accomplished by the pumping of fluid collected in the bore hole by mechanical or fluid mechanical means. Several methodologies are known to provide this pumping action, each with its own limitations.
[0005] In a one methodology, a rod extends down the well from a surface location to terminate in a production zone of a well, where it is connected to a rod pump. The rod pump generally includes a piston and piston-housing configuration, selectively ported to the well fluid production zone, and production tubing extending from the pump to the earths surface. The rod is attached to the piston, and it reciprocates upwardly and downwardly, such that during a down stroke thereof, well fluids received in the pump housing are compressed and ported to a production tube, and during the upstroke, a check valve opens and allows well fluids into the piston cavity to be compressed on the next down stroke. Thus the recovery rate is dependant upon the stroke of the rod and the number of strokes of the rod per unit of time. This type of pump is typically used where the flow requirement of the pump is relatively low. These pumps are most effective for pumping medium to light clean oil but they lose efficiency as the oil viscosity increases, and they experience rapid wear if the pumped fluids contain abrasive media.
[0006] A second methodology is the use of a rotary positive displacement pump, typically called a progressive cavity pump. These pumps typically use an offset helix screw configuration, where the threads of the screw or “rotor” portion are not equal to those of the stationary, or “stator” portion over the length of the pump. By insertion of the rotor portion into the stator portion of the pump, a plurality of helical cavities is created within the pump that, as the rotor is rotated with respect to the pump housing, cause a positive displacement of the fluid through the pump. To enable this pumping action, the surface of the rotor must be sealingly engaged to that of the stator, which also typically is an integral part of the housing. This sealing provides the plurality of cavities between the rotor and stator, which “progress” up the length of the pump when the rotor rotates with respect to the housing. The sealing is typically accomplished by providing at least the inner bore or stator surface of the housing with a compliant material such as nitrile rubber. The outermost radial extension of the rotor pushes against this rubber material as it rotates, thereby sealing each cavity formed between the rotor and the housing to enable positive displacement of fluid through the pump when rotation occurs relative to the rotor-housing couple. Rotation of the rotor relative to the housing is accomplished by extending a rod, rotatably driven by a motor at the surface, down the borehole to connect to one end of the rotor exterior of the housing. At the lower end of the pump, an inlet is formed, and at the upper end of the pump, production tubing extends from the pump outlet to a receiving means on the surface, such as a tank, reservoir or pipeline. Because of the compliant and durable stator, progressive cavity pumps are more tolerant of viscous and abrasive fluids than other pump types.
[0007] One issue encountered with progressive cavity pumps is degradation of the pump components at high temperatures. To operate effectively over a sustained period of time, the compliant seal between the rotor and housing must maintain its resiliency. The material used for effectively forming this seal, typically nitrile rubber, encounters temperature-based resiliency breakdown if the ambient to which the material is exposed exceeds approximately 250 degrees F. Thus, in fields with naturally occurring high downhole temperatures and in fields where steam injection is used to free heavy oil, such as tar sand, from the formation, the temperature of the oil will often exceed the 250 degree F. threshold, and rapid pump degradation will occur. Although other sealing materials have been used to form the rotor-to-pump seal, they are compromises in terms of either performance or cost, and thus have received limited success in the marketplace.
[0008] A third artificial lift methodology is the use of the electric submersible pump. These pumps typically are composed of a multi-stage centrifugal pump attached to an electric motor that is located in the wellbore. The motor is located immediately below the pump, with a rotary drive shaft running up from the motor through a seal that prevents the entry of wellbore fluid into the motor. The pump is normally located near the bottom of the well, proximate the production zone, with the inlet at the lower end, and the outlet at the upper end of the pump, discharging into the production tubing. An electrical power cord from the surface is clamped to the outside of the production tubing and the pump, so that it can deliver power through the annulus of the wellbore, to the motor. In high temperature pumping applications such as those mentioned above, the temperature of the well plus the normal temperature rise of an electric motor tends to cause thermal breakdown of the electrical insulation, causing failure of the motor or the wiring. As a result, the use of this artificial lift method is limited to wells having a moderate temperature.
[0009] As an example, the temperature operating limits on the pump components have limited the use of progressive cavity pumps and electric submersible pumps in the recovery of heavy oil from boreholes. These deposits are often referred to as “tar sand” or “heavy oil” deposits due to the high viscosity of the hydrocarbons which they contain. Such tar sands may extend for many miles and occur in varying thicknesses of up to more than 300 feet. The tar sands contain a viscous hydrocarbon material, commonly referred to as bitumen, in an amount, which ranges from about 5 to about 20 percent by weight. Bitumen is usually immobile at typical reservoir temperatures. Although tar sand deposits may lie at or near the earth's surface, generally they are located under a substantial overburden or a rock base which may be as great as several thousand feet thick. In Canada and California, vast deposits of heavy oil are found in the various reservoirs. The oil deposits are essentially immobile, and are therefore unable to flow under normal natural drive, primary recovery mechanisms. Furthermore, oil saturations in these formations are typically large, which limits the injectivity of a fluid (heated or cold) into the formation.
[0010] Several in-situ methods of recovering viscous oil and bitumen have been the developed over the years. One such method is called Steam Assisted Gravity Drainage (SAGD) as disclosed in U.S. Pat. No. 4,344,485 which is incorporated by reference herein in its entirety. The SAGD operation requires placing a pair of coextensive horizontal wells spaced one above the other at a distance of typically 5-8 meters. The pair of wells is located close to the base of the viscous oil and bitumen. The span of formation between the wells is heated to mobilize the oil contained within that span which is done by circulating steam through each of the wells at the same time. The span is slowly heated by thermal conductance.
[0011] After the oil in the span is sufficiently heated, it may be displaced or driven from one well to the other, thereby establishing fluid communication between the wells. The steam circulation through the wells is then terminated. Steam injection at less than formation fracture pressure is initiated through the upper well and the lower well is opened to produce liquid thereto from the formation. As the steam is injected, it rises and contacts cold oil immediately above the upper injection well. The steam gives up heat and condenses; the oil absorbs heat and becomes mobile as its viscosity is reduced. The condensate and heated oil drain downwardly under the influence of gravity. The heat exchange occurs at the surface of an upwardly enlarging steam chamber extending up from the wells, as oil and condensate are produced through the recovery wellbore at the bottom of the steam chamber. In a heavy oil reservoir, the preferred pumping means to produce such oil in the recovery borehole would typically be the progressive cavity pump. However, since the recovery wellbore of a SAGD system is typically at a temperature in the range of 300 to 450 degrees Fahrenheit, the use of the progressive cavity pump with optimal sealing materials for pump longevity and cost is not possible due to the temperature.
[0012] A further method of well bore fluid recovery is known as jet pumping. This methodology takes advantage of the venturi effect, whereby the passage of fluid through a venturi causes a pressure drop, and the oil being recovered is thereby brought into the fluid stream. To accomplish this in a well, a hollow string is suspended in the casing to the recovery level, and a venturi is provided in a housing adjacent an orifice which extends into the oil in the bore, a fluid is flowed down the string and through the venturi and thence back out the well in the space between the string and casing. The oil is pulled into the stream and carried to the surface therewith, whence it is separated from the fluid. The fluid is recycled and again directed down the well. This technique suffers from poor system energy efficiency and the need for extensive equipment at the surface, the cost of which typically exceeds the value of the oil which may be recovered. Jet pumping is less effective with viscous fluids than with lighter fluids because it is more difficult for a venturi effect to pull viscous fluids into the jet pump mixing tube, and the mixing tube must be substantially longer to accomplish adequate fluid mixing in the pump.
[0013] An additional method of well bore fluid recovery is gas-assisted lifting, in which natural gas is compressed at the surface and made to flow through the annulus between the production tubing and the well casing to the lower portion of the well, where it is injected through an orifice into the production tubing. The addition of this gas to the liquid in the production tubing reduces the density of the hydrostatic column of produced fluid so that the natural pressure of the formation is then adequate to drive the produced fluid to the surface. This technique suffers from the fact that uniform mixing of the gas with the fluid in the production tubing is more difficult to achieve in viscous fluids. Gas-assisted lifting is further limited by the fact that it depends upon there being adequate pressure in the reservoir to lift the hydrostatic column of reduced density fluid to the surface.
[0014] Therefore, there exists in the art a need to provide enhanced artificial lifting methods, techniques and apparatus, having a greater return on investment and or durability.
SUMMARY OF THE INVENTION
[0015] The present invention generally provides methods, apparatus and article for the improved artificial lifting of fluids, particularly useful in high temperature environments, using a pump driven from a remote location, such as a progressing cavity pump.
[0016] In one embodiment, the invention provides a footed borehole, having an entry location from a first borehole and extending in a generally offset direction from the first borehole, and also having a horizontal component forming a landing region which would, during production, be a collection point for oil in the footed borehole. A pump, drivable from a remote location, is landed in the footed borehole in a position where the oil may collect, but at a sufficient distance from the end of the foot of the borehole that a harsh temperature condition in the foot is ameliorated at the landed location.
[0017] In one embodiment, the pump is driven by a rotating rod extending at least from the pump to the well head. Further, the pump may be a progressing cavity pump, and further, the pump is positioned at a location sufficiently near the producing interval such that the flowing pressure drop between the producing interval and the pump is minimized. A surface control on the pumping system senses the intake pressure at the pump via a downhole pressure sensor. The pump control then adjusts the pumping cycle to maintain the intake pump pressure within acceptable limits such that pump intake pressure is minimized without allowing the pump to reduce the fluid level to a level that would allow the pump to ingest gas instead of liquid. As the water-laden well fluids approach the pump, the reduced pressure at the pump causes the water in the well fluids to vaporize at the flash point temperature corresponding with the pressure at the pump. This vaporization removes heat from the fluid and causes it to be cooled to the flash temperature of the water at the pump intake pressure. Therefore by controlling the intake pressure of the pump, the intake fluid temperature can be limited as well if the fluid is water-laden as is the case with SAGD operations, thus allowing conventional flexible materials to be used in the pump. For example, the flash point of water at 50 psia (35 psig) is 281 degrees F. If the pump intake pressure is maintained between 20 psig and 35 psig, then sufficient condensed water in the well fluids would vaporize at 281 degrees F., thus removing heat and limiting the temperature of the well fluids.
[0018] In a further embodiment, the footed borehole is located in a field in which steam injection is occurring, and the temperature of the oil in the production zone of the footed bore exceeds the breakdown temperature of the material used for the seal between the rotor and housing. In a steam injection field, the steam typically is injected into the production zone in the saturated (not superheated) condition. As the well fluid rises toward the surface, the static head of liquid in the casing decreases, causing the pressure of the liquid to decrease. The decrease in pressure of the fluid causes the evolution of steam vapor from the liquid phase, this then resulting in a natural decrease in the temperature of the well fluid so that the temperature of the fluid exactly matches the saturation temperature of steam at the new pressure. The pump is positioned in the evolving region, and therefore in a lower temperature portion of the wellbore so that the pump is able to operate in the lower temperature, and therefore less severe temperature environment portion of the well. This allows the use of pumps that would not be practical for use in the higher temperature region of the well, but it does require that provision be made to pump the evolved vapor phase, or allow the vapor to bypass the pump and proceed up the annulus to the surface.
BRIEF DESCRIPTION OF THE DRAWINGS
[0019] 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.
[0020] FIG. 1 is a schematic view of a wellbore, having an offset or “footed” section, located in a steam assisted recovery field, into which a pump is suspended;
[0021] FIG. 2 is a partial sectional view of a progressive cavity pump; and
[0022] FIG. 3 is a sectional view of the downhole portion of the wellbore shown in FIG. 1 .
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0023] Referring to FIG. 1 , there is shown in schematic representation, a producing oil well having a first borehole 10 extending from a well head 12 at the opening of the borehole to the surface 14 , and a lower terminus 16 . At least one footed borehole 18 extends outwardly from first borehole 10 , although multiple such footed boreholes may be in place and in communication with borehole 10 .
[0024] Each footed borehole 18 includes an entrance section 20 at which the footed borehole 18 deviates from the centerline 17 of the first borehole 10 (in FIG. 1 adjacent the lower terminus 16 thereof), from which the footed borehole 18 extends to form a foot 22 terminating at toe 24 . The angle between the centerline of the first borehole 10 and the footed borehole changes between the foot 22 and entrance section 20 , such that a generally curved portion 26 is located between foot 22 and entrance section 20 . As the curved section begins to decrease in curvature as the generally straight section of the foot 22 is reached, heel 30 is positioned. The generally horizontal first borehole 10 is preferably cased, whereas the footed borehole 18 is not cased, but is preferable screened, such as by placing a plurality of cylindrical screen elements (not shown) therein to allow the passage of fluid therein, but to block a portion of any sand or other particulates which will otherwise flow into the footed borehole 18 . Although the first borehole 10 is shown extending downwardly into the earth beyond the opening of footed borehole 18 therefrom to reach other possible producing locations, first borehole 10 and footed borehole 18 may be formed as one continuous borehole, such that no continuing portion of first borehole 10 is provided.
[0025] Referring still to FIG. 1 , a tube 32 , having a rod 34 suspended therein, is hung from wellhead 12 and extends into the first bore 10 to terminate within footed borehole 18 . At the end of tube 32 terminating within the footed borehole 18 is located a pump 38 . In the preferred embodiment, pump 38 is a progressing cavity pump, which is powered downhole by rod 34 . Rod 34 extends through the entire length of the tube 32 , terminating at one end thereof in engagement with the rotor (shown in FIGS. 2 and 3 ) of the progressing cavity pump, and at the second end thereof in engagement with a drive motor 40 , typically an electric motor, shown schematically and located adjacent the wellhead 12 . As rod 34 is rotated, it causes the pump to pressurize the well fluids and pump them up the tube 32 through which rod 34 extends. To enable rod 34 to rotate in tube 32 without interfering engagement with the tube 32 , a plurality of stabilizers 42 may be provided in the tube through which the rod extends to space rod 34 from the inner surface of tube 32 , and which stabilizers are substantially permeable to oil being pumped therethrough from pump 38 to well head 12 . Additionally, a pressure sensor 30 is provided on the exterior of the pump, and communicates the pressure at the pump intake to a controller 33 at the surface 14 through wire 31 .
[0026] Referring now to FIG. 2 , the details of the pump 38 are shown. In the preferred embodiment, pump 38 generally includes an outer housing 46 which together with elastomeric portion 50 forms a stator 44 of the pump 38 . Stator 44 is preferably formed as a helical female elastomeric portion 50 , formed as a helical path within a cylindrical envelope to create a helical bore 52 , and having an elastomeric section which, at a minimum, is an elastomeric coating on the inner bore surface of the stator housing 46 . Received within helical bore 52 is a helical rotor 48 , which has a generally helical outer profile 58 . Rotor 48 likewise includes eccentricity, i.e. an offset of its center of rotation from the centerline of the stator 44 , such that the rotor 48 sweeps through a cylindrical envelope of equal or slightly greater diameter of the cylindrical envelope of the inner face of the elastomeric section 50 of stator 44 . Thus, as the rotor 48 turns within stator 44 , a series of helical cavities 60 are formed between stator 44 and rotor 48 , which cavities “progress” down the longitudinal bore of the pump 38 as relative rotation between stator 44 and rotor 48 occurs. The first cavity of the pump 38 is connected to an inlet 59 , which is fluidically connected to the wellbore. The last cavity 61 formed between rotor 48 and stator 44 empties well fluids under pressure into the tubing 32 . Well fluids are propelled into the tubing 32 under sufficient pressure to raise them to the wellhead 12 . The length of the pump 38 , the pitch of the rotor 48 and stator 44 , and thus the number of helical cavities 60 formed in the pump 38 , are selected to ensure that the pressure in the pump exit provides sufficient hydrostatic head to propel well fluids to the surface 14 . The relative rotational motion between rotor 48 and stator 44 is typically in the range of 60 to 400 rpm.
[0027] Referring still to FIG. 2 , pump housing 46 is coupled to the tube 32 , such as by mating threads and thus threaded engagement, and is thus locked against rotation thereby. Rod 34 , extending within tube 32 , is coupled to rotor 56 via threaded coupling 66 , connecting rotor 48 to rod 34 . Thus, when rod 34 is rotated, rotor 48 turns within stator 44 to pump well fluids from inlet 59 , progressively through cavities 60 , and thence to exit cavity 62 , through outlet conduit 64 , and thus up through tube 32 to the wellhead 12 , where it is recovered into a tank, reservoir or pipeline.
[0028] Referring now to FIG. 3 , there is shown the pump 38 in location at the heel 30 section of footed wellbore 18 . As shown in FIG. 3 , pump 38 is landed at the base of the heel 30 , positioned at the lowest side of the footed borehole 18 . The pump 38 is positioned within the well fluid, such as oil, steam vapor, and steam condensate, such that the liquid extends above the pump 38 in the bore 18 to at least a position above the pump 38 . Thus the oil extends to an interface 70 , at which the oil meets a pressure near that of atmospheric pressure with the additional pressure of gas and steam vapor in the tube 32 , i.e., a natural height based upon the hydrostatic pressure of the oil in the footed borehole 18 . In the embodiment shown, the footed wellbore 18 extends in a field in which secondary recovery of fluid is being undertaken, typically using heat in the form of steam to free the oil from the surrounding formation. Thus, typically, steam is injected at very high pressure from a steam generator (not shown) into injection wellbores (not shown) above the footed borehole 18 , thereby reducing the viscosity of the heavy oil which it encounters by raising the temperature thereof. This heavy oil, having an elevated temperature, then flows under gravity to the footed borehole 18 located below the injection borehole for recovery thereof. The heavy oil will enter the footed borehole 18 at high temperatures, typically in the 300 to 500 degree Fahrenheit range, and having steam condensate mixed with the oil.
[0029] As the heal 30 of the footed borehole 18 has a slope, the oil collected therein with have an ambient pressure gradient from the lowest most portion 78 of the footed borehole 18 to the interface 70 , with the pressure being highest at the lowest most extension thereof into the earth, and lowering to the interface pressure at the interface 70 .
[0030] The steam condensate mixed with the oil will remain liquid until the pressure of the column of oil in the footed borehole 18 is no longer sufficiently high to maintain steam in liquid state at the localized temperature and pressure of the steam. Thus, when the steam reaches a portion of the column of the oil at which it can no longer exist in a liquid or dissolved state, a portion of it vaporizes, and when steam vaporizes it lowers the temperature of the surrounding ambient, in this case the oil. The steam forms bubbles 80 the condensate evolves vapor due to the reduced pressure, and the bubbles form first at a zone 82 in the oil column at which the hydrostatic pressure and temperature conditions dictate that they shall come out of solution. Thus the bubbles 80 , at formation in the zone 82 , cool the oil and the bubbles thence flow upwardly in the oil column and thence into the open bore of the well. The bubbles 80 also preferentially rise in the oil to the upper surface 84 of the footed wellbore 18 , and thus pass above the pump 38 and they are therefore not sucked into the pump entry when pump 38 is operating. The oil at the location of the pump 38 , cooled by the evolution of steam vapor, is thus in a temperature range below 280 degrees Fahrenheit, and thus the use of nitrile rubber as the stator coating material is enabled.
[0031] The position of the pump 38 within the footed wellbore is determined by a consideration of the expected interface 70 position within the well bore and the expected temperature of the oil entering the footed wellbore, from which a hydrostatic head pressure profile can be calculated. As a result, the likely location at which bubbles will form and thus cool the oil can be predicted. Furthermore, the pump is operated to pump the hot fluids in the wellbore 18 such that the pressure at the pump inlet remains in the 20 to 35 psig range, which ensures that the pump will not run dry, but also ensures that the temperature of the oil adjacent the pump is cooled by the evolution of steam bubbles 80 from the fluid. The lower end of the pressure range ensures that some well fluid is present above the pump 32 inlet 59 , equivalent to approximately 5 psi of head less the pressure exerted by steam and gas in the wellbore. The upper limit of the pressure range is selected to ensure that the pressure is sufficiently low, at the temperatures the fluid is expected to be present in the footed borehole 18 , such that bubbles 80 will form adjacent to the inlet 59 to cool the fluid surrounding the pump 32 . Thus, the controller controls the operation of drive motor 40 , to cease pumping operation when the lower limit of the range is reached, and increase the pumping rate by increasing the rotation of the drive shaft 34 and thus reduce the quantity of fluid above the pump to ensure bubble evolution adjacent the pump, when the upper pressure limit is approached. The pump 38 is located in a position above (i.e., closer to the wellhead) than where the bubbles form, such that the formed bubbles will have risen to the upper surface of the footed wellbore 18 before they reach the pump 38 . As the zone 82 in which the bubbles form will extend some vertical space in the zone, the pump 38 should be located horizontally offset from the uppermost portion of the zone 82 . Thus vapor can be prevented from entering, and vapor locking, the pump 38 , while the advantages of the cooling of the oil by the cooling effect of the steam vaporizing from solution, can be taken advantage of to use lower temperature resistance seal materials in the pump 38 . Alternatively, the pump intake could be shielded, where bubble 80 formation is likely to occur below the pump 32 , such as if the pump 32 is positioned in a vertical wellbore such as wellbore 10 .
[0032] By positioning the progressing cavity pump 38 in a position where the oil in the borehole is naturally cooled, the pump may be used with nitrile rubber sealing components, and thus the cost and durability advantages of these materials may be enjoyed in the recovery of well fluids from steam injection fields.
[0033] 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. | Oil is recovered from a borehole using a pump having limited high temperature breakdown resistance. The pump is located in a borehole having a cooling zone, in which the temperature of the well fluid is reduced to, or below, the temperature at which the temperature breakdown resistance of the pump is commercially acceptable. In one embodiment, the pump is a positive displacement pump which is mechanically driven from the well head location, such as through a rotating rod. The cooling zone is provided by positioning and controlling the pump to maintain a sufficiently low pressure at the pump intake to cause a portion of the liquid well fluid to vaporize prior to entry of the liquid into the pump, creating bubbles which pass upwardly in the wellbore in a zone passing the pump. The evolution of the vapor cools the well fluid to the acceptable temperature. | 4 |
CROSS-REFERENCE TO RELATED APPLICATION
[0001] This application claims priority from provisional application Ser. No. 60/749,456, filed Dec. 12, 2005.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] This invention relates generally to a hermetic feedthrough terminal pin assembly, preferably of the type incorporating a filter capacitor. More specifically, this invention relates to terminal pins comprising palladium or palladium alloys for incorporated into feedthrough filter capacitor assemblies, particularly of the type used in implantable medical devices such as cardiac pacemakers, cardioverter defibrillators, and the like, to decouple and shield internal electronic components of the medical device from undesirable electromagnetic interference (EMI) signals. The terminal pin feedthrough assembly provides a hermetic seal that prevents passage or leakage of fluids into the medical device.
[0004] 2. Prior Art
[0005] Feedthrough assemblies are generally well known in the art for use in connecting electrical signals through the housing or case of an electronic instrument. For example, in an implantable medical device, such as a cardiac pacemaker, defibrillator, or neurostimulator, the feedthrough assembly comprises one or more conductive terminal pins supported by an insulator structure for passage of electrical signals from the exterior to the interior of the medical device. The conductive terminals are fixed into place using a gold brazing process, which provides a hermetic seal between the pin and insulative material. Conventionally, the terminal pins have been composed of platinum or a combination of platinum and iridium. Platinum and platinum-iridium alloys are biocompatible and have good mechanical strength, which adds to the durability of the feedthrough. However platinum is a precious metal that creates a manufacturing cost barrier.
[0006] The replacement of platinum and platinum alloys by palladium and its alloys offers several advantages. First, platinum has a density of 21.45 grams/cc. Palladium has a density of 12.02 grams/cc. These materials are priced by weight, but used by volume, which means that palladium has a significant cost advantage over platinum. Secondly, platinum and palladium have nearly equivalent mechanical properties. After high temperature brazing, there is no significant degradation in the mechanical properties of palladium, such as in strength and elongation, in comparison to platinum. Palladium also has comparable soldering and welding characteristics, and it has good radiopacity. Finally, previous research indicates that palladium is biocompatible under both soft tissue and bone studies. Palladium and additive materials that are typically combined with it to form alloys are regarded as chemically inactive.
SUMMARY OF THE INVENTION
[0007] In a preferred form, a feedthrough filter capacitor assembly according to the present invention comprises an outer ferrule hermetically sealed to either an alumina insulator or fused glass dielectric material seated within the ferrule. The insulative material is also hermetically sealed to at least one terminal pin. That way, the feedthrough assembly prevents leakage of fluid, such as body fluid in a human implant application, past the hermetic seal at the insulator/ferrule and insulator/terminal pin interfaces.
[0008] According to the invention, the terminal pin of a feedthrough assembly, and preferably of a feedthrough filter capacitor assembly, are composed of palladium. The terminal pin can be a uniform wire-type structure of palladium or an alloy thereof, or it can comprise an outer palladium coating over a core material. The core can be of platinum, tantalum, niobium or other electrically conductive materials commonly used in implantable medical devices. In that respect, palladium is an alternative corrosion resistant material that provides a considerably less expensive terminal pin than conventional platinum or platinum-iridium terminal pins while still achieving the same benefits of biocompatibility, good mechanical strength and a reliable hermetic feedthrough seal. Replacement of platinum and platinum-iridium terminal pins with a palladium-based material is done without employing complex and expensive manufacturing operations and, generally, without the addition of a secondary manufacturing process.
[0009] These and other objects and advantages of the present invention will become increasingly more apparent by a reading of the following description in conjunction with the appended drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0010] FIG. 1 is a perspective view of a feedthrough assembly embodying the novel features of the invention.
[0011] FIG. 2 is an enlarged sectional view taken along line 2 - 2 of FIG. 1 .
[0012] FIG. 3 is a cross-sectional view of one embodiment of a terminal pin 16 comprising an outer layer of palladium 16 A coating an inner core 16 B of electrically conductive material.
[0013] FIG. 4 is a cross-sectional view taken along line 4 - 4 of FIG. 2 .
[0014] FIG. 5 is a cross-sectional view taken along line 5 - 5 of FIG. 2 .
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0015] Referring now to the drawings, FIGS. 1 and 2 show an internally grounded feedthrough capacitor assembly 10 comprising a feedthrough 12 supporting a filter discoidal capacitor 14 . The feedthrough filter assembly 10 is useful with medical devices, preferably implantable devices such as pacemakers, cardiac defibrillators, cardioverter defibrillators, cochlear implants, neurostimulators, internal drug pumps, deep brain stimulators, hearing assist devices, incontinence devices, obesity treatment devices, Parkinson's disease therapy devices, bone growth stimulators, and the like. The feedthrough 12 portion of the assembly 10 includes terminal pins 16 that provide for coupling, transmitting and receiving electrical signals to and from a patient's heart, while hermetically sealing the interior of the medical instrument against ingress of patient body fluids that could otherwise disrupt instrument operation or cause instrument malfunction. While not necessary for accomplishing these functions, it is desirable to attach the filter capacitor 14 to the feedthrough 12 for suppressing or decoupling undesirable EMI signals and noise transmission into the interior of the medical device.
[0016] More particularly, the feedthrough 12 of the feedthrough filter capacitor assembly 10 comprises a ferrule 18 defining an insulator-receiving bore surrounding an insulator 20 . Suitable electrically conductive materials for the ferrule 18 include titanium, tantalum, niobium, stainless steel or combinations of alloys thereof, the former being preferred. The ferrule 18 may be of any geometry, non-limiting examples being round, rectangle, and oblong. A surrounding flange 22 extends from the ferrule 18 to facilitate attachment of the feedthrough 10 to the casing (not shown) of, for example, one of the previously described implantable medical devices. The method of attachment may be by laser welding or other suitable methods.
[0017] The insulator 20 is of a ceramic material such as of alumina, zirconia, zirconia toughened alumina, aluminum nitride, boron nitride, silicon carbide, glass or combinations thereof. Preferably, the insulating material is alumina, which is highly purified aluminum oxide, and comprises a sidewall 24 extending to a first upper side 26 and a second lower side 28 . The insulator 20 is also provided with bores 30 that receive the terminal pins 16 passing there through. A layer of metal 32 , referred to as metallization, is applied to the insulator sidewall 24 and the sidewall of the terminal pin bores 30 to aid a braze material 34 in hermetically sealing between the ferrule 18 and the insulator 24 and between the terminal pins 16 and the insulator 24 , respectively.
[0018] Suitable metallization materials 32 include titanium, titanium nitride, titanium carbide, iridium, iridium oxide, niobium, tantalum, tantalum oxide, ruthenium, ruthenium oxide, zirconium, gold, palladium, molybdenum, silver, platinum, copper, carbon, carbon nitride, and combinations thereof. The metallization layer may be applied by various means including, but not limited to, sputtering, electron-beam deposition, pulsed laser deposition, plating, electroless plating, chemical vapor deposition, vacuum evaporation, thick film application methods, and aerosol spray deposition, and thin cladding. Parylene, alumina, silicone, fluoropolymers, and mixtures thereof are also useful metallization materials.
[0019] Non-limiting examples of braze materials include gold, gold alloys, and silver. Then, if the feedthrough 10 is used where it will contact bodily fluids, the resulting brazes do not need to be covered with a biocompatible coating material. In other embodiments, if the brazes are not biocompatible, for example, if they contain copper, they are coated with a layer/coating of biocompatible/biostable material. Broadly, the biocompatibility requirement is met if contact of the braze/coating with body tissue and blood results in little or no immune response from the body, especially thrombogenicity (clotting) and encapsulation of the electrode with fibrotic tissue. The biostability requirement means that the braze/coating remains physically, electrically, and chemically constant and unchanged over the life of the patient.
[0020] According to one embodiment of the invention, the terminal pins 16 consist of palladium and its alloys. Non-limiting examples include pure palladium and alloys comprising from about 50% to about 99% palladium along with other elements including those from the platinum group such as ruthenium, rhenium, and iridium, or refractory metals such as molybdenum, and boron, and combinations thereof.
[0021] Mechanical properties of the terminal pin 16 can be tailored to a desired mechanical performance by adjusting the amounts of the elemental additions in the palladium alloy. For example, age hardening can be improved by increasing the amount of ruthenium. Other additions to the palladium alloy such as platinum, gold, copper, and zinc, for example increase the alloy's ability to be cold worked to achieve a higher tensile strength or to allow the alloy to be annealed and to increase its elongation characteristics.
[0022] In another embodiment of the present invention, the terminal pins 16 comprise an exterior outer coating 16 A of palladium and palladium alloys applied as a coating to a core 16 B of a second, electrically conductive material other than palladium ( FIG. 3 ). Preferably, the core material 16 B is selected from the group consisting of niobium, tantalum, nickel-titanium (NITINOL®), titanium, particularly beta titanium, titanium alloys, stainless steel, molybdenum, tungsten, platinum, and combinations thereof. The means of coating may include sputtering, cladding, and or plating. The coating may be applied through a process of sputtering, electron-beam deposition, pulsed laser deposition, plating, electroless plating, chemical vapor deposition, vacuum evaporation, thick film application methods, aerosol spray deposition, and thin cladding.
[0023] For example, it is known that niobium readily oxidizes. This means that when it is used as a terminal pin material secondary operations are necessary in order to effect a hermetic braze with low equivalent series resistance (ESR). Providing a palladium outer coating 16 A over a niobium core 16 B in an evacuated atmosphere prior to formation of niobium oxide means that the thusly constructed terminal pin can be directly brazed into the insulator 20
[0024] Although the terminal pin 16 is shown having a circular cross-section that is not necessary. The terminal pin 16 can have other cross-sectional shapes including square, triangular, rectangular, and hexagonal, among others. Nonetheless, the core 16 B has a diameter of from about 0.002 inches to about 0.020 inches and the outer coating 16 A has a thickness of from about 0.5 μm inches to about 0.002 inches.
[0025] Up to now, terminal pins for feedthrough assemblies used in implantable medical devices, and the like, have generally consisted of platinum. However, replacement of platinum and platinum alloys by palladium and its alloys offers several advantages. For one, the density of platinum is 21.45 g/cc in comparison to palladium at 12.02 g/cc. Both of these materials are priced by weight, but used by volume. Therefore palladium has significant cost advantage over platinum. Secondly, palladium has comparable electrical conductivity to platinum (platinum=94.34 l/mohm-cm, palladium=94.8 l/mohm-cm and gold=446.4 l/mohm-cm). Thirdly, palladium and platinum have significantly equivalent mechanical properties. After high temperature brazing, there is no significant degradation of mechanical properties such as strength and elongation. Fourthly, palladium is both solderable and weldable. Fifthly, palladium has good radiopacity characteristics. This is an important consideration for viewing the terminal pin during diagnostic scans such as fluoroscopy. Lastly, but every bit as important, palladium is biocompatibility. Previous research indicates a variety of positive biocompatibility studies (both soft tissue and bone) for all elements used. Palladium and its alloy additives are regarded as chemically inactive.
[0026] As further shown in FIGS. 2, 4 and 5 , the feedthrough filter capacitor 10 includes the filter capacitor 14 that provides for filtering undesirable EMI signals before they can enter the device housing via the terminal pins 16 . The filter capacitor 14 comprises a ceramic or ceramic-based dielectric monolith 36 having multiple capacitor-forming conductive electrode plates formed therein. The capacitor dielectric 36 preferably has a circular cross-section matching the cross-section of the ferrule 18 and supports a plurality of spaced-apart layers of first or “active” electrode plates 38 in spaced relationship with a plurality of spaced apart layers of second or “ground” electrode plates 40 . The filter capacitor 14 is preferably joined to the feedthrough 12 adjacent to the insulator side 26 by an annular bead 42 of conductive material, such as a solder or braze ring, or a thermal-setting conductive adhesive, and the like. The dielectric 36 includes lead bores 44 provided with an inner surface metallization layer. The terminal pins 16 pass there through and are conductively coupled to the active plates 38 by a conductive braze material 46 contacting between the terminal pins 16 and the bore metallization. In a similar manner, the ground plates 40 are electrically connected through an outer surface metallization 48 and the conductive material 42 to the ferrule 18 .
[0027] It is appreciated that various modifications to the invention concepts described herein may be apparent to those of ordinary skill in the art without departing from the scope of the present invention as defined by the appended claims. | Terminal pins comprising an outer coating of palladium coating a core material other than of palladium for incorporated into feedthrough filter capacitor assemblies are described. The feedthrough filter capacitor assemblies are particularly useful for incorporation into implantable medical devices such as cardiac pacemakers, cardioverter defibrillators, and the like, to decouple and shield internal electronic components of the medical device from undesirable electromagnetic interference (EMI) signals. | 7 |
FIELD OF THE INVENTION
The present invention relates generally to the manufacturing of tape with an integral primer. More specifically, the invention relates to a method and apparatus for laminating adhesive tapes with an integral primer, and to tape manufactured by this method.
BACKGROUND OF THE INVENTION
Most conventional tapes for heavy industrial or commercial use have been manufactured using a calendering process wherein multiple layers (adhesive, base material, and release liner) are pressed together to form a laminated tape. The calendering process uses multiple rollers to press the bulk materials into sheets and then laminate them into a composite. This process is not conducive to applying a thin coating of substantially solids primer into the laminate between the adhesive and the release liner. Tapes with a integral primer are useful in numerous applications, including wrapping pipelines, maritime use, construction, and roofing applications. However, such tapes are more difficult to manufacture than standard commercial tape.
Other methods were examined that proved less successful than the present method. Spraying the substantially solids primer directly onto the adhesive after the base material and adhesive had been laminated was unworkable due to the high viscosity of the substantially solids primer. Applying a thin coating of substantially solids primer onto the laminate using a roller coating was unworkable because the primer has an aggressive tack that would not allow the primer to release from the coating roll to the laminate, even when the primer was heated. Coextruding multiple layers (base material, adhesive, and substantially solids primer) while laminating a release liner also had difficulties due to the high viscosity and aggressive tack of the primer.
Therefore, another method and apparatus had to be developed to manufacture tape with an integral primer.
SUMMARY OF THE INVENTION
It is an object of this invention to provide a method and apparatus that overcomes the disadvantages of the prior methods as described above. It is specifically contemplated that the method of this invention will overcome the disadvantages recited herein with respect to the high viscosity and aggressive tack of the primer while providing a commercially useful method of manufacturing a tape with an integral primer.
In broad terms, the method and apparatus of this invention provide a process of laminating a release liner and tape with a thin integral primer. The apparatus of the present invention comprises multiple extrusion dies and driven rollers having an arrangement that supplies a stream of molten adhesive and a separate stream of primer that is laminated between a film of base material and a release liner, which is laminated between cooled rollers. It contemplates using standard accumulators and material feed sources. The apparatus further includes a means for providing continuous flows of molten adhesive and primer by including pressurized pipelines to deliver the adhesive and primer to the respective dies. The apparatus still further includes separate electronically-controlled drives for the rollers that provide differential speeds to the feed rollers and cooled pinch rollers so that the lamination occurs with minimal residual stress in the finished, cooled laminate tape. The rollers are further controlled in terms of temperature, pressure, thickness, and tension. The invention results in an adhesive tape that is unstressed and relatively wrinkle free. The method and apparatus can be effectively used for producing high quality tapes that contain a thin layer of integral primer. Such tapes do not require separate primers to be used during the application of the tape.
The apparatus and method of this invention can be used to manufacture the Primerless Pipeline Coating Tape as described in U.S. Pat. No. 5,516,584. It is also contemplated that the apparatus and method can used in manufacturing roofing materials, marine wraps, construction materials, and highway repair tapes, as well as other tapes with integral primers as may be found useful in the future. Such tapes produced by this method may reduce the harmful environmental effects of using primers and may drastically decrease the time for applying tapes by eliminating the application of a primer or waiting for the primer to set.
BRIEF DESCRIPTION OF THE DRAWINGS
The above mentioned and other features of this invention and the manner of obtaining them will become more apparent and the invention itself will be best understood by reference to the following description of an embodiment of the invention taken in conjunction with the accompanying drawings in which FIG. 1 is a schematic view showing the process of making tape.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring to FIG. 1, a process is shown for laminating tape with a thin integral primer. The method of making tape includes conveying a base material 20 and applying an adhesive 22 on the top side the base material 20 with an adhesive extrusion die 24. The base material 20 may include bituminous materials, a wide range of plastics, and woven fabric, such as cloth. Adhesive 22 may include standard materials with adhesive qualities as plentiful in the art.
Next, a release liner 26 is applied with a primer 28 by means of a primer extrusion die 30. The primer 28 is surface receptive with an aggressive tack. An example of such a primer is disclosed in U.S. Pat. No. 5,516,584, which is owned by a common assignee as the present invention and is incorporated herein by reference. The release liner can be a variety of material that do not stick to the adhesive and have release characteristics, such as a silicon coated paper or plastic, such as a polypropylene.
The release liner 26 coated with primer 28 is rotated around a portion of liner assist roller 32. The base material 20 with adhesive 22 is aligned and laminated with the release liner 26 coated with primer 28 between liner assist roller 32 and roller 34 so that the adhesive coated side 38 and the primer coated side 40 are directed inward and between the base material 20 and the release liner 26. The resulting combination 42 is directed through two pinch rollers 34 and 36. It should be apparent that this method is part of a larger process that must include mixing adhesive and primer and pumping them to the extrusion dies. The rollers are independently electronically controlled.
The apparatus 18 of this invention, as schematically shown in FIG. 1, contains a base material supply source 50 to provide the base material 20. Source 50 is preferably a roll; however, other sources are plentiful. The base material 20 may be formed and rolled until it is ready for the production of tape, or it may come directly from a fabricator.
The base material 20 may proceed through a series of control cylinders. Preferably, the control cylinders 52 are arranged into an accumulator 54. Accumulators 54 as known in the art take up slack in the base material 20 and allow for changing of supply source rolls. As the base material 20 proceeds, an adhesive extrusion die 24 allows for the application of an adhesive 22. The selection of an extrusion die is not critical to this invention. Numerous die means are known including single and twin screw extruders, off-batch extruders, and the like. Multi-manifold dies are also an option. The adhesive extrusion die 24 is connected to a pressurized pipeline or tubing through which the molten adhesive is pumped (not shown).
A release liner 26 is introduced from a source and preferably through an accumulator (not shown). Preferably, the liner 26 is properly directed by a control cylinder 56 that directs the release liner 26 to a liner assist roller 32. A primer extrusion die 30 applies a primer 28 to the release liner 26. A release liner overcomes the manufacturing and rolling concerns caused by the tackiness of the primer 28. The release liner 26 contacts the rollers and is guided through the roll stack (Rollers 32, 34, and 36) so that the primer 28 does not contact the roll stack during the manufacturing process. The primer extrusion die 30 is attached to an integral primer mixer (not shown) through pressurized pipelines/tubing and pumps (also not shown) as necessary to provide a primer 28 in the appropriate manner.
The liner assist roller 32 operates in conjunction with a roller 34 to laminate the base material 20 with the release liner 26 with the primer 28 and the adhesive 22 in between. Rollers 32 and 34 may operate as chill rollers. The combination 42 passes through pinch rollers 34 and 36. Rollers 32, 34, and 36 (the roller stack) are independently electronically controlled so that speed and temperature of each roller is independently set. Also, the rollers 32, 34, and 36 are adjustable so that tension, pressure, and thickness are controlled.
The resulting tape may pass through a double unwind feed turret that is known in the art (not shown) and wrap on a product roll 58.
The apparatus 18 preferably includes adjustable, electronically-controlled drives for the roll and rollers that provide differential speeds to the feed rolls and the roller stack so that the lamination occurs with minimal residual stress in the finished, cooled laminated tape. A slight differential in speed, possible due to independent drives, has been found useful. The sheer may be controlled and adjusted to produce the desired tape and take into account the thickness and properties of the materials. Also, the temperature or chilling of the rollers can be controlled. Finally, the distance between rollers of the roll stack is adjustable to accommodate or to form tape of the desired thickness. The result is an adhesive tape that is unstressed and relatively wrinkle free, which may contain a thin layer of integral primer, to replace tapes that require separate primers during application of the tape.
While in the foregoing specification this invention has been described in relation to a preferred embodiment thereof. It will be apparent to those skilled in the art that the invention is susceptible to additional embodiments and that certain of the details described herein can be varied considerably without departing from the basic principals of the invention. | A method and apparatus providing a process of laminating tape with a thin integral primer to a release liner. The apparatus of the present invention comprises multiple extrusion dies and adjustable driven rollers having an arrangement that supplies a stream of molten adhesive and a separate stream of primer that is laminated between a film of base material and a release liner, which is laminated between cooled rollers to form a tape. | 1 |
RELATED APPLICATIONS
Not Applicable
FEDERALLY SPONSORED RESEARCH
Not Applicable
MICROFICHE APPENDIX
Not Applicable
SEQUENCE LISTING OR PROGRAM
Not Applicable
BACKGROUND OF THE INVENTION
(1) Field of the Invention
The invention is a portable barricade device designed to disable vehicles attempting to cross the barricade.
(2) Description of the Related Art
This invention relates to vehicular barricades and vehicular disablement devices. Law enforcement authorities, military personnel, and all other persons involved in security and enforcement are often confronted with the task of securing vehicular access-ways (e.g., roads, parking lots, walkways, etc.). This is becoming more of an issue as terrorist acts continue throughout the world. Americans are more aware of the threat of domestic violence in the United States after the September 11 th attack on the Twin Towers. The need for improved methods and devices to counter and guard against specific acts of vehicular terrorism (e.g., car bombs, armed and armored vehicles) is paramount. It was with this counter-terrorism thought in mind that the following security measure device came into being.
When streets are blocked off to prevent access, the most common means is to place a saw-horse type barricade at the access-way or utilize a concrete barricade. The saw-horse type of barricade works fine as an administrative barricade. It is portable and easy to set-up, but lacks strength and effectiveness should a vehicle choose to pass—the vehicle will simply run through the saw-horse. The concrete barricade is a very effective means of barricading a street, however it is difficult to use as it requires heavy equipment to place such a barricade and is quite time-consuming to do so. During World War II, devices similar to the double-cross barricade were found on beach fronts to impede the progress of troop landing amphibious vehicles.
Other prior art disclosures include different techniques to impede or prevent a vehicle's access. U.S. Pat. No. 3,346,713, to Walker, Apr. 18, 1944, discloses a caltrop with hollow spikes or “arms” designed to puncture pneumatic tires. This device is not designed to damage a vehicle's engine or engine components.
U.S. Pat. No. 2,313,388, to McDonald, Mar. 9, 1943, discloses a vehicle-impeding device for use against wheeled or tracked vehicles. The invention consists of a cup-like device, with several prongs extending upward and outward, with the intent to catch in solid or inflatable rubber tires in such a manner as to be difficult to disengage therefrom, and which, when so disengaged, causes considerable damage to the tires. This device is not designed to damage a vehicle's engine or engine components.
U.S. Pat. No. 6,206,608 B1, to Blevins, Mar. 27, 2001, discloses a vehicle disabling device for use against wheeled vehicles. The invention consists of a “carpet” of spikes designed to deflate tires and obstruct the free movement of the wheels. This device is not designed to damage a vehicle's engine or engine components.
U.S. Pat. No. 5,921,703, to Becker, Jul. 13, 1999, discloses a new and improved caltrop designed to disable vehicles with pneumatic tires. This device is not designed to damage a vehicle's engine or engine components.
U.S. Pat. No. 5,639,178, to Wilson, Jun. 17, 1997, discloses a vehicle barrier designed to control access to or from a vehicle park, parking space or controlled authorized zone. This device is not portable.
U.S. Pat. No. 5,975,791, to McCulloch, Nov. 2, 1999, discloses a vehicle security gate apparatus and method of operating same, to inhibit and control vehicular access. This device is not portable.
It is an object of the present invention to provide a barricade device that destroys a vehicle's engine and/or its components, ensuring full and total disablement of the vehicle, rather than simply attacking the vehicle's tires/tracks.
It is another object of the invention to provide a barricade device that lifts a vehicle off the ground and tilts it onto its side or back, stopping all forward progress of the vehicle.
It is another object of the invention to provide a barricade device that is easily stored, assembled, and deployed.
It is another object of the invention to provide a barricade device that is easily manufactured.
These and other objects of the invention will be apparent after reading the ensuing disclosure.
SUMMARY OF THE INVENTION
An object of the present invention is to provide a reliable device for securing vehicular access-ways and disabling automotive-type vehicles refusing to heed established barricades. By either destroying engine components, or gaining a position under the vehicle so as to lift the vehicle up (and its front wheels off the ground), or gaining a position under the vehicle such that the vehicle tilts on its side or tips over onto its back, the invention causes full disablement of the vehicle.
In its preferred embodiment, the invention has a rigid structure with the strength to easily support the weight of an automobile. In this preferred embodiment, the invention is completely portable and easy to assemble within minutes by a single individual. Rather than attacking a vehicle's tires/tracks, this device destroys the engine and/or its components, ensuring full and total disablement of the vehicle, and/or lifts vehicle off the ground or tilts it onto its side or back. The invention is easily stored and deployed, and easily manufactured.
DESCRIPTION OF THE DRAWINGS
(1) FIG. 1 shows a perspective view of the double-cross barricade in operation, according to the preferred embodiment.
(2) FIG. 2A shows the design and assembly of Rail-B to Rail-A.
(3) FIG. 2B shows the proper installation of Rail-B into Rail-A.
(4) FIG. 3A shows the design and assembly of Rail-C to Rail-A and Rail-B.
(5) FIG. 3B shows the proper installation of Rail-C into Rail-B and Rail-A.
LIST OF DRAWING REFERENCE NUMBERS
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DETAILED DESCRIPTION OF THE INVENTION
A preferred embodiment of the double-cross barricade is illustrated in FIG. 1, which shows a perspective view of the double-cross barricade in operation. Three structural steel I-beams, referred to as Rail-A, Rail-B, and Rail-C, are connected at a central axis position at perpendicular right angles to each other, forming a large three-dimensional, X-shaped barricade. As the structural steel I-beams, Rail-A, Rail-B, and Rail-C, are each approximately 1.219 meters (four feet) in length, upon final construction, the double-cross barricade is at a height sufficient to rip through the engine chassis of a family size, four-door sedan automobile upon an automobile's impact, and allowing the barricade to lodge itself under the vehicle, thereby lifting the vehicle off its front wheels, and/or tipping the vehicle onto its side or back.
Additional embodiments include increasing the size in length and/or girth of the steel I-beams for greater effectiveness against larger vehicles, including pickup trucks, vans, armored cars, buses, semi-trucks and trailers, etc.
Although steel is the preferred material of construction for the double-cross barricade, other materials may be used, provided they have the strength and structural support to accomplish the goal of the double-cross barricade. This goal is to rip and tear through an automobile chassis, and support the weight of the vehicle, without the barricade coming apart.
The central axis or connecting point location of the double-cross barricade may be designed and located at a position other than the center of the beams to facilitate the barricade's use on different forms of terrain or against a specific vehicular threat.
(1) Objects and Advantages
Several objects and advantages of the double-cross barricade include:
(a) Rather than attacking a vehicle's tires/tracks, the double-cross barricade destroys the engine and/or its components, ensuring full and total disablement of the vehicle.
(b) The double-cross barricade lifts the vehicle off the ground and tilts it onto its side or back, ensuring full and total disablement of the vehicle.
(c) The double-cross barricade is easily stored.
(d) Being portable, the double-cross barricade is easily deployed.
(e) The double-cross barricade is easily manufactured.
(f) One person can easily assemble the double-cross barricade.
(2) Presently Preferred Method for Constructing the Presently Preferred Embodiment of the Double-Cross Barricade
The double-cross barricade consists of three major rail weldments: Rail-A, Rail-B and Rail-C, FIG. 1, with two locking pin sets. Each locking pin set consists of a standard 1.905 cm×15.24 cm (¾ inch×6 inch) hitch pin, with a hitch pin clip (TSC# 02-6882-8). Hitch pin clips are also known as hair pins. Two standard 1.984 cm ({fraction (25/32)} inch) inside diameter×(1 inch) outside diameter×5.00 cm (1{fraction (31/32)} inch) long top link bushings (TSC# 02-6844-6) are also required.
(A) Rail-A Construction
Rail-A, in FIG. 2A, is constructed of a 10.16 cm (4 inch) hot roll wide flange structural I-beam 1 A 1.219 meters (four feet) long for a standard length. Longer lengths for providing effective barricades against larger vehicles may also be used. A locking pin brace 4 A 1.27 cm×3.175 cm (½ inch×1¼ inch) hot roll steel, 9.207 cm (3⅝ inch) long is used for support after installing Rail-B. Rail guide 2 A is 5.08 cm×5.08 cm×0.794 cm (2 inch×2 inch×{fraction (5/16)} inch) hot roll angle iron, 9.207 cm (3⅝ inch) long. The rail guides are square and parallel with the edge of structural I-beam 1 A. To ensure that the angle iron guides are square and parallel to each other, a locating fixture built specifically for this purpose is used. Another rail guide 3 A is also made of 5.08 cm×5.08 cm×0.794 cm (2 inch×2 inch×{fraction (5/16)} inch) hot roll angle iron, 9.207 cm (3⅝ inch) long. The rail guide 3 A must also be square and parallel with the edge of structural I-beam 1 A. Located on the end opposite the arrow, on this guide, is a notch approximately 0.953 cm×4.286 cm (⅜ inch×1{fraction (11/16)} inch) to allow for clearance of the welded bead on angle iron rail guide 3 B on Rail-B, when the two parts are assembled. The two rail guides 2 A, 3 A must be welded on the inside before the locking pin brace 4 A for Rail-B is installed. The hand-welded “Arrow” 9 A and the hand-welded letter “A” 10 are used to aid in the correct assembly of Rail-A and Rail-B.
(B) Rail-B Construction
Rail-B, in FIG. 2A, is constructed of a 10.16 cm (4 inch) hot roll wide flange structural I-beam 1 B 1.219 meters (four feet) long for a standard length. Longer lengths for providing effective barricades against larger vehicles may also be used. A locking pin brace 4 B 1.27 cm×3.175 cm (½ inch×1¼ inch) hot roll steel, 9.207 cm (3⅝ inch) long is used for support after installing Rail-C. Rail guides 2 B, 3 B are 5.08 cm×5.08 cm×0.794 cm (2 inch×2 inch×{fraction (5/16)} inch) hot roll angle iron, 9.207 cm (3⅝ inch) long. The rail guides are square and parallel with the edge of structural I-beam 1 B. One slide stop 5 0.953 cm×0.953 cm (⅜ inch×⅜ inch) cold roll steel, 8.89 cm (3½ inch) long, must be square with the edge of Rail-B and in-line with the inside edge of the rail guide 3 B. To ensure that the angle iron guides and slide stop are square and parallel to each other, a locating fixture built specifically for this purpose is used. The two rail guides 2 B, 3 B must be welded on the inside before the locking pin brace 4 B for Rail-C is installed. One locking pin hole 12 B is drilled through both flanges, which are aligned with each other at a distance from the slide stop 5 to allow clearance for Rail-A and the wall thickness of bushing 7 B. The hand-welded “Arrow” 9 B and the hand-welded letter “B” 11 and three hand-welded prevent buttons 13 B, 13 B′, 13 B″ are used to aid in the correct assembly of Rail-A and Rail-B.
(C) Rail-C Construction
Rail-C, in FIG. 3A, is constructed of a 10.16 cm (4 inch) hot roll wide flange structural I-beam 1 C 1.219 meters (four feet) long for a standard length. Longer lengths for providing effective barricades against larger vehicles may also be used. A slide stop 14 C 5.08 cm×5.08 cm×0.794 cm (2 inch×2 inch×{fraction (5/16)} inch) hot roll angle iron, 9.207 cm (3⅝ inch) long, is square and parallel with Rail-C. To ensure that the slide stop is square and parallel with Rail-C, a locating fixture built for this purpose is used. A locking pin hole 12 C is drilled through both flanges and aligned with each other at a distance from the inside edge of slide stop 14 C to allow clearance for both Rail-A and Rail-B plus the wall thickness of bushing 7 C. The hand-welded “Arrow” 9 C and the hand-welded letter “C” 15 and three hand-welded prevent buttons 13 C, 13 ′, 13 C″ are used to aid in the correct assembly of Rail-C to Rails-A and B.
(D) Painting Rails-A, B, and C
Wire brush, sand or vapor blast all three rails. Wipe clean with a dry cloth and spray paint one coat of primer paint. Let dry, lightly sand and paint with a red fluorescent paint. Other colors may be used.
(3) Assembly and Positioning of the Double-Cross Barricade
(A) Assembling Rail-B to Rail-A
Lay Rail-A on the ground at a 45 degree angle to the side of the road for the appropriate assembly set-up angle 16 (FIG. 2A) with the left end back and the right end forward, with the rail guides 2 A, 3 A facing up. The hand-welded letter “A” 10 on the left hand side and the hand-welded “Arrow” 9 A points away from the assembler's feet placement 17 and to the left at 45 degrees. Place Rail-B into the Rail-A rail guides 2 A, 3 A by placing the “Arrow” end of Rail-B into the rail guide first. This is the end without the hand-welded prevent button 13 B (FIGS. 2A, 3 A). With the hand-welded “Arrow” 9 A and the hand-welded letter “B” 11 on top, slide Rail-B into the rail guides in the direction of the “Arrows” until the slide stop 5 (FIG. 2B) on the bottom of Rail-B, contacts the edge of Rail-A. This will form a big “X” in the road. Slide the locking pin 6 B through the top of Rail-B, through the drilled locking pin hole 12 B until it comes to a stop at its shoulder. Then slide the bushing 7 B over the end of the locking pin 6 B and snap in the hitch pin clip 8 B in the small hole at the end of the locking pin 6 B (FIGS. 2A, 2 B, 3 A, and 3 B.) As an option, Rail-A can be manufactured with the bushing 7 B already welded in place.
(B) Assembling Rail-C to Rail-B and Rail-A
With Rail-B on the right hand side of the assembler's feet placement 17 (FIG. 2B) and Rail-A in front, step over the letter “A” welded on Rail-A. Turn around and with the help of another person, stand the unit up in the direction of the “Arrow”. This is the assembly set-up direction 19 . The rail guides 2 B, 3 B (FIG. 3A) for Rail-C will be on the right hand side of the standing big “X”. With Rail-A the closest rail to the person inserting Rail-C (which is now the opposite side of the previous assembly), insert Rail-C into Rail-B, FIG. 3 A. FIG. 3A is viewed from the end of Rail-A for clarity. (See 18 , FIG. 2B, for direction of this assembly view.) With the hand-welded “Arrow” 9 C and the hand-welded letter “C” 15 on the top right and the slide stop 14 C on the top left (the Rail-A side), slide Rail-C in, until the slide stop 14 C is hooked over the flange of Rail-A and the inside edge of slide stop 14 C (FIG. 3B) is as far as it will go against the outside edge of Rail-A. Slide the remaining locking pin 6 C (or hitch pin) through the top of Rail-C, through the locking pin hole 12 C on the other side until it comes to a stop at its shoulder. Then slide the other bushing 7 C over the end of the locking pin 6 C and snap in the hitch pin clip 8 C in the small hole at the end of the locking pin 6 C. As an option, Rail-B can be manufactured with the bushing 7 C already welded in place.
(C) Setting up the Double-Cross Barricade Alone
If the assembler is setting up the double-cross barricade without an assistant, this procedure should be followed: Assemble Rail-A and Rail-B as stated above. With Rail-B on the right hand side of the assembler's feet placement 17 (FIG. 2B) and Rail-A in front, step over the letter “A” welded on Rail-A to the second position. Turn around and raise the assembled unit in the direction of the arrow, and the assembly set-up angle 19 . With the big “X” standing on two legs, walk around to the other side, supporting the standing unit as you do so. Lay the big “X” back down on the ground, pulling it towards you. In other words, turn the big “X” over onto the Rail-B side. Now step back over to the second position and insert the end of Rail-C into Rail-B with the hand-welded “Arrow” 9 C and hand-welded letter “C” 15 on the top right and the slide stop on the top left (the Rail-A side). Drop it vertically until it makes contact with the ground. Using Rail-C as a lever, pull Rail-C towards you until it is parallel with the ground and the big “X” is standing once again. Hold and support the big “X” with your left hand and slide Rail-C in with your right hand, until the slide stop 14 C is hooked over the flange of Rail-A and the inside edge of the slide stop 14 C is as far as it will go against the outside edge of Rail-A. Install locking pin 6 C (or hitch pin) through the top of Rail-C, through the locking pin hole 12 C on the other side until it comes to a stop at its shoulder. Slide the other bushing 7 C over the end of the locking pin 6 C and snap in the hitch pin clip 8 C in the small hole at the end of the locking pin 6 C. The main difference between the one-man procedure and the two-man procedure is a means of starting Rail-C into Rail-B on the ground, instead of standing up, without having the assembled Rail-A and Rail-B falling over while trying to insert Rail-C.
(D) Operation and Positioning of the Double-Cross Barricade
Roll the completed unit back down towards the assembler, on three points so the hand-welded “Arrows” 9 A, 9 B, 9 C on all three rails are pointing upward. Turn the double-cross barricade with the tops of Rail-A and Rail-B facing the traffic side. (See FIG. 1 ). This is the strongest set-up, although other configurations are possible and acceptable. If a vehicle attempts to break through the barricade, it will strike the upper-most portions of Rail-A and Rail-B, causing the two ends to rip into the chassis of the vehicle causing extensive damage to the engine and its components. The ends of the tripod base (from Rail-A and Rail-B) will dig into the ground upon impact. The double-cross barricade will then turn over due to the vehicle's momentum, rotating the bottom of Rail-C to the top, impaling the bottom of the vehicle, lifting it off the ground, and ending its forward motion.
(4) Conclusions, Ramifications, and Scope
In conclusion, the double-cross barricade combines the best features in various prior art in one invention. As a barricade, it is portable, extremely strong, easily seen, easy to manufacture, easy to store and deploy, and easy to assemble. As a vehicular disabling device, it can rip through an on-coming vehicle's chassis upon impact and cause extreme damage to the engine and its various components. It is strong enough to lodge under an on-coming vehicle and lift the vehicle off the ground, tip it to one side or the other, and with enough force, even on its back.
By increasing the size of the barricade, its functionality may encompass larger automotive vehicles, including vans, pickup trucks, armored cars, and semi-trucks/trailers. By changing the position of the central axis point (other than the center of the rails), different configurations of the double-cross barricade may be developed based on terrain, weather, threat, etc.
The double-cross barricade has been described with reference to a preferred embodiment, but various modifications and variations would be obvious to one of ordinary skill in the art. The description of the preferred embodiment is not intended to be limited. | Portable vehicular barricade and vehicle disabling device consisting of three structural steel I-beams joined together at a central axis location at right angles to each other to form a large, 3-dimensional, x-shaped structure. When placed on the ground, the barricade will come to rest on three of the structural steel I-beam ends, forming a stable tripod I-beam base. The remaining three structural steel I-beam ends will be facing upwards and out from the central axis of the device. Upon impact of an on-coming vehicle, the tripod I-beam ends will dig into the ground while the steel I-beam ends facing upwards and out will tear through the vehicle's chassis and engine components, and at the same time, roll over with the vehicle's momentum to cause the barricade device to lodge itself under the vehicle, impeding any further forward motion of the vehicle, and possibly forcing the vehicle on its side or back. | 5 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation-in-part application of application Ser. No. 13/406,741 filed Feb. 28, 2012, which is a continuation application of application Ser. No. 12/204,894 filed Sep. 5, 2008, which is a nonprovisional application of and claims benefit of the filing date of provisional application No. 60/970,677, filed Sep. 7, 2007, the contents of each of which are incorporated herein by reference in their entireties.
BACKGROUND OF THE INVENTION
[0002] Orthodontics is the branch of dentistry that specializes in the diagnosis, prevention and treatment of the dental and facial irregularities. The technical term for these problems is “malocclusion.”
[0003] Malocclusions can be treated by treatment modalities using fixed or removable appliances, or a combination of both. Fixed appliances are known as braces, and they are most common form of treatment for malocclusion. Braces involve moving teeth into desired position through a system of brackets and wires that apply pressure on teeth and shift in a certain direction. Conventional removable appliances are composed of wires attached to a plastic/polymer base and can be removed by the patient. Malocclusions can also be corrected with the removable appliance named as “aligners,” “tooth positioners” or “correctors.”
[0004] A tooth positioner is a clear and removable orthodontic appliance.
[0005] Tooth positioners were developed over 50 years ago and are made of clear plastic to guide teeth after fixed braces therapy or for minor adjustment of the teeth.
SUMMARY OF THE INVENTION
[0006] A method for forming a tooth positioner for repositioning at least one tooth of a patient includes providing a dental arch cast of a patient having at least one tooth to be repositioned, separating at least one tooth from the dental arch cast, including the at least one tooth to be repositioned to provide at least one separated cast tooth having a crown part and a stump representing a root, fixing a pin in the stump part of the at least one separated tooth, and in any non-separated teeth, each of the pins extending outwardly from the stump part, reconstructing the dental arch cast of the patient by aligning the separated teeth to correspond to the alignment in the patient's mouth and holding the pins in a material that may be softened by heat, heating at least an area of the material that may be softened by heat in which the pin fixed in the at least one tooth to be repositioned is held to soften the area, applying force to at least the pin fixed in the at least one tooth to be repositioned to move the at least one tooth to be repositioned in a desired direction to obtain a realigned arch, cooling the material that may be softened by heat; and forming a tooth positioner corresponding to the realigned arch.
[0007] The tooth positioner can be used by having the patient wear the tooth positioner for a period of time.
[0008] A method for reviewing a diagnostic setup for an orthodontic treatment, includes providing a dental arch cast of a patient having at least one tooth to be repositioned, separating at least one tooth from the dental arch cast, including the at least one tooth to be repositioned to provide at least one separated cast tooth having a crown part, and a stump representing a root, fixing a pin in the stump part of the at least one separated tooth, and in any non-separated teeth, each of the pins extending outwardly from the stump part, reconstructing the dental arch cast of the patient by aligning the separated teeth to correspond to the alignment in the patient's mouth and holding the pins in a material that may be softened by heat, taking a first photograph of the reconstructed dental arch cast, heating at least an area of the material that may be softened by heat in which the pin fixed in the at least one tooth to be repositioned is held to soften the area, applying force to at least the pin fixed in the at least one tooth to be repositioned to move the at least one tooth to be repositioned in a desired direction to obtain a realigned arch, taking a second photograph of the realigned arch, morphing the first and second photographs, and reviewing the morphed photographs to review a diagnostic setup for an orthodontic treatment.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF DRAWINGS
[0009] FIG. 1 shows an example of an upper impression taken in an impression tray.
[0010] FIG. 2 shows an example of an upper epoxy cast.
[0011] FIG. 3 shows a polymer shell made on an upper epoxy cast.
[0012] FIGS. 4 and 5 show a modified cutting technique and cast teeth separated, trimmed &finished.
[0013] FIG. 6 shows a customized pin fixed inside a cast tooth.
[0014] FIGS. 7A and 6B show front and side views, respectively, of teeth having pins inserted in an upper zero aligner (ZA).
[0015] FIGS. 8A and 8B are top and perspective views, respectively, of an arch reconstruction frame (ARF).
[0016] FIGS. 9A and 9B are side perspective and top perspective views, respectively, of a custom made vertical articulator.
[0017] FIGS. 10A-10G show successive steps of the zeroing technique of the present invention.
[0018] FIG. 11 shows the heads of the pins will be exposed at the end of this process shown in FIGS. 10A-10G .
[0019] FIGS. 12A and 12B show, respectively, the whole upper arch reconstructed and position of teeth inside the patient's mouth.
[0020] FIGS. 13A-13D show a bite registration/bite setting technique and reconstruction of the lower arch using arch reconstruction frames (ARFs) and a vertical articulator (VA).
[0021] FIG. 14 shows lower arch reconstructed having zero aligner (ZA) on it at the end of the process shown in FIGS. 13A-13D .
[0022] FIGS. 15A and 15B show front views, respectively, of the upper and lower processed arches together and the occlusion in the patient's mouth while FIGS. 15C and 15D show side views, respectively, of the upper and lower processed arches together and the occlusion in the patient's mouth.
[0023] FIG. 16 shows half portion of thermoplastic material and arch (half on the left in this example) covered with insulating material.
[0024] FIG. 17 shows a cross-section through the arch with an upper/top insulating layer, wax in the middle, and a lower/bottom insulating layer.
[0025] FIGS. 18A and 18B show, respectively, a top perspective view and a close perspective view of a digital picture recorder (DPR) lodged with reconstructed upper arch.
[0026] FIG. 19 shows the platform of digital picture recorder (DPR) with vertical bars and magnetic system.
[0027] FIG. 20 shows the upper and lower reconstructed arches mounted with the help of vertical bars and magnetic/ball system on platform of a digital picture recorder (DPR).
[0028] FIGS. 21A and 21B show, respectively, a side perspective view and a top perspective view of a movement platform.
[0029] FIGS. 22A-22B show mounting teeth having pins into wax, heating and using a customized mechanical movement device to move a pin along with tooth in a measured manner in the desired direction.
[0030] FIGS. 23A-23F show examples of mechanical movement devices.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0031] This description is directed to those skilled in the orthodontics art. In this description, contributing parts and procedures that are well known to those skilled in the art or otherwise not essential to an understanding of the invention are described without any unnecessary detail to avoid any confusion. For example, before working on any dental Impression, the orthodontist should disinfect it with a disinfection solution as is known in the art. Since this disinfecting treatment is known in the art, this and similar treatments and products have not been mentioned here.
[0032] The method of the present invention will now be described with reference to the attached Figures.
[0033] Upper and lower impressions of a patient with malocclusion are taken by the doctor, e.g., dentist or orthodontist, in impression trays as shown in FIG. 1 , which shows an impression 10 of the upper teeth 11 and gum 12 being taken in an impression tray 13 . Impressions are poured with a casting material e.g., epoxy resin, to make upper and lower dental arch casts, an upper cast 14 with upper cast teeth 11 ′ being shown in FIG. 2 . Epoxy is a tough synthetic resin, containing epoxy groups, that sets with specific time and further hardens when heat or pressure is applied. The casting material, e.g., epoxy resin is poured in the impression approximately 2 mm above the gum margin as shown in the circled area in FIG. 1 . After the setting time as specified by the manufacturer, casts are removed from the impressions one by one. Excessive epoxy material is removed from the epoxy casts and any voids created during the casting process are filled out. This produces the exact replica of patient's teeth in the form of epoxy casts, an upper cast being shown in FIG. 2 . Both the epoxy casts are placed into occlusion on any flat surface. If required, their bases are trimmed in such a way that when both arches are placed in occlusion their bases are parallel to each other.
[0034] Excessive epoxy material is removed from the epoxy casts, the upper cast 14 of which is shown in FIG. 2 , and any voids are filled out. Each epoxy cast, e.g., cast 14 , is placed in a thermoforming machine (e.g., a Biostar thermoforming machine) to make the polymer shell 15 on it as shown in FIG. 3 . In the method described herein, the polymer shell 15 is referred to as a “Zero Aligner” (“ZA”). The polymeric shells 15 fit snugly over the casts 14 , thus creating a plural of the dental casts or zero aligners (ZAs). Zero aligners 15 (ZAs) are trimmed following the curves of scalloped gum line to remove all the excess plastic material around the cast, leaving about 1 mm below the gum line on buccal side, while excess material is left within the configuration of arch form. This is to give more strength to the polymeric shells to ensure the accuracy in the later process as shown in FIG. 3 . Zero Aligners (ZAs) are then removed from the epoxy casts and stored to be used in the later procedures. The drawings show the manner in which the upper cast and its Zero Aligner (ZA) are made; the lower cast and its Zero Aligner (ZA) are made in a corresponding manner.
[0035] Each cast tooth 11 ′ is then carefully separated out of epoxy casts using different cutting tools and given a tooth ID so that they are not misplaced later.
[0036] A modified cutting technique, referred to herein as the butterfly technique, can be applicable in some cases. In this technique as shown in FIGS. 4 and 5 , only those teeth 11 ′ are segmented which are desired to be moved or are mal-aligned, while the rest of teeth 11 ″ are united together, with a metal bar 16 . As shown in FIGS. 4 and 5 , the butterfly technique is used and a joining bar 16 connects the posterior teeth 11 ″ with each other which are not desired to be cut.
[0037] As shown in FIG. 5 , all the separated teeth 11 ′ are trimmed and finished in such a way that at the end, a tooth crown 17 with a short stump 18 representing the root is created with a cervical margin 18 ′ there between. The quality of the segmented teeth is verified to check if any tooth structure is lost during this process and is rebuilt if required according to the original dentition.
[0038] Holes are drilled at the base of each tooth stump 18 , and in each uncut segment if the butterfly technique is used, and custom made pins 19 are inserted and fixed inside each hole by using bonding material. The pins 19 have a head 20 , a threaded or corrugated body 21 , first and second band parts 22 and 22 ′, and a neck 22 ″ there between. It can be advantageous to use a pin that has a 5 mm head 20 , an 10 mm threaded or corrugated body 21 , first and second band parts 22 and 22 ′ of 2 mm and 1 mm, respectively, a neck 22 ″ of 1 mm, and a 4 mm tail (the portion not shown within the cast tooth 11 ′).
[0039] Each cut tooth/uncut segment is then manually inserted in already made zero aligners (ZAs) into their own respective position as shown in FIGS. 7A and 7B for upper arch.
[0040] A custom made frame, shown in FIGS. 8A and 8B , referred to herein as an “arch reconstruction frame” (“ARF”) is placed in a custom made articulator, shown herein in FIGS. 9A and 9B , referred to herein as a “vertical articulator” (“VA”) as shown in FIG. 10A .
[0041] Arch reconstruction frames (ARFs) 23 are custom made frames made up of varying materials and thickness according to their use as shown in FIGS. 8A and 8B . Each arch reconstruction frame 23 has a frame body 24 and alignment holes 25 . Each arch reconstruction frame 23 may have metallic balls 26 and screw holes 27 .
[0042] The vertical articulator 28 , as shown in FIGS. 9A and 9B , has a base 29 and two vertical bars 30 attached to a base 29 . The vertical bars 30 help to secure the arch reconstruction frames (ARFs) 23 during the arch reconstruction procedure and reloading the upper and lower arches in relation as it exists in patient's mouth (bite setting procedure).
[0043] Arch reconstruction frames (ARFs) 23 are provided on the vertical articulator 28 as shown in FIG. 10A and provide a casting boundary which holds and shapes the thermoplastic material, this thermoplastic material shaped in a horseshoe shape provides a medium for holding teeth with the help of their associated fixtures in their original as well as modified positions.
[0044] A non-sticky doughy material 31 is poured inside the arch reconstruction frame (ARF) 23 secured at the base 29 of the vertical articulator (VA) 28 as shown in FIG. 10B . One non-sticky doughy material that may be used is alginate. Alginate is a type of impression material that is used in dental practice to take the dental impressions. It is available in powder form and when mixed with water it becomes semisolid and then takes a rubbery consistency when finally set within a few minutes.
[0045] As shown in FIG. 10C , one set of cast teeth 11 ′, 11 ″, upper teeth in this example, along with pins 19 are placed inside the zero aligner (ZA) 15 into a freshly poured alginate impression layer 31 in such a way that heads 20 of the pins 19 dip inside the freshly poured semisolid layer alginate layer 31 . After a few minutes, the alginate material layer 31 gets solidified. Then another arch reconstruction frame (ARF) 23 ′ is placed on the top of already placed arch reconstruction frame (ARF) 23 in the vertical articulator 28 as shown in FIG. 10D . Any potential gaps between two arch reconstruction frames (ARFs) 23 , 23 ′ are sealed and blocked, e.g., with any block out material. Alginate/Silicone material 32 is used to fulfill this purpose as shown in FIG. 10E .
[0046] A thermoplastic material 33 , such as wax, is melted and poured inside the arch reconstruction frame (ARF) 23 ′ over the alginate layer 31 in such a way that all the threaded/corrugated portions 21 of pins 19 are provided within and surrounded by molten wax 33 . The wax 33 is poured up to the band part 22 of the pins 19 as shown in FIG. 10F . The wax 33 cools down after a few minutes; this cooling process can be accelerated by application of some cooling agent. Once the wax 33 cools down and gets hard, the block out material 32 which was used to seal and block the gap between two arch reconstruction frames (ARFs) is removed. The second arch reconstruction frame (ARF) 23 ′ is taken out of the vertical articulator 28 , as shown in FIG. 10G and 11 . The second arch reconstruction frame (ARF) 23 ′ has pins 19 embedded in the wax 33 up to the band part 22 of the pins 19 , while heads 20 of the pins will be exposed as the alginate 31 will not let the wax 33 come in contact with the pin heads 22 and, at the same time, the alginate 31 will not stick to the pin heads 20 . This technique is termed “Pin's head exposing technique.”
[0047] After the second arch reconstruction frame (ARF) 23 ′ is taken out of the vertical articulator 28 , the entire upper arch has been reconstructed. FIGS. 12A and 12B show, respectively, the whole upper arch reconstructed and position of teeth inside the patient's mouth. As can be seen comparing FIG. 12A with FIG. 12B , the position of teeth in the reconstructed arch achieved after going through this process will essentially be same as the position of teeth inside the patient's mouth or the position of teeth in an impression taken by the doctor (see FIG. 1 ). This technique is referred to herein as “Zeroing”. The ZA is then cut and separated from the upper reconstructed arch.
[0048] In the following discussion, bite registration means the inter-arch relationship of upper and lower teeth of the patient. An accurate bite registration is necessary to establish the proper occlusal relationship during mounting of the two arches. It is also necessary while correcting malocclusions so that teeth can be reconstructed and adjusted without creating inter-arch interferences. A negative replica of this relationship may be provided by the treating dentist or orthodontist along with the patient's impressions. In dentistry, occlusion refers to the manner in which the teeth of upper and lower arches come together when the mouth is closed.
[0049] Two new arch reconstruction frames (ARFs) 34 , 35 are mounted one by one at the base 29 of a vertical articulator 28 . Any potential gaps between two arch reconstruction frames (ARFs) 34 , 35 are sealed and blocked out, e.g., with a block out material 32 ′. The arch reconstruction frame (ARF) 23 ′ having upper cast teeth 11 ′, 11 ″ are then placed in the vertical articulator 28 in such a way that heads of the pins 20 face upwards as shown in FIG. 13A . Then a zero aligner (ZA) 15 having lower teeth with attached pins 19 is brought in close approximation with the upper reconstructed arch held in the arch reconstruction frame (ARF) 23 ′. Once the desired position representing the occlusion of patient is achieved, sticky material 36 (see FIG. 13D ) is used to glue the two arches in that position as shown in FIG. 13B . To maximize the accuracy of this inter-arch relationship, the patient's bite registration and photographs can be used.
[0050] A freshly mixed alginate layer is placed inside the arch reconstruction frame (ARF) 35 already placed at the base of the vertical articulator (VA) 28 . Then, the whole assembly of upper reconstructed arch held in arch reconstruction frame (ARF) 23 ′ along with the glued lower zero aligner (ZA) 15 having lower cast teeth in it is brought to the base of a vertical articulator 28 in such a way that heads of the pins 19 of the lower teeth dip inside the freshly mixed alginate material. Once the alginate is solidified, melted wax 33 ′ is poured inside the arch reconstruction frame (ARF) 34 over the alginate layer in such a way that all of the threaded/corrugated portion 21 of pins 19 of the lower cast teeth are dipped inside the wax 33 ′ and threaded/corrugated portion 21 of the pins 19 is surrounded by molten wax. The wax 33 ′ is poured up to the band part 22 of pins 19 of lower teeth as shown in FIGS. 13C and 13D . The wax 33 ′ cools down after a few minutes; this cooling process can be accelerated by application of some cooling agent. Once the wax 33 ′ cools down and gets hard, the glue 36 used to unite the upper reconstructed arch held in the arch reconstruction frame (ARF) 23 ′ and the lower zero aligner (ZA) 15 and the block out material 32 ′ that was used to seal and block the gap between two arch reconstruction frames (ARFs) 34 , 35 are removed. Upper arch reconstruction frame (ARF) is taken out of the vertical articulator leaving behind the lower reconstructed arch enclosed in lower zero aligner (ZA) 15 as shown in FIG. 14 . The lower zero aligner 15 is then cut and removed from the lower reconstructed arch.
[0051] In order to attain the same vertical position every time whenever desired, two screws 38 can be provided at the boundary of arch reconstruction frame (ARF) in screw holes 27 (see FIG. 20 ).
[0052] The above-described process provides upper and lower reconstructed arches, with each tooth 11 ′ and uncut segment 11 ″ having a pin 19 , the corrugated portion 21 of pins 19 being surrounded by wax 33 , 33 ′ and heads 20 of the pins 19 exposed. Moreover, when the two arches are placed inside the vertical articulator (VA) 28 , they represent the occlusion present inside the patient's mouth. The occlusion of reconstructed arches is established with the help of specially designed arch reconstruction frames (ARFs) 23 ′, 34 and vertical articulator (VA) 28 as shown in FIGS. 15A-15D . FIGS. 15A and 15B show front views, respectively, of the upper and lower processed arches (held in arch reconstruction frames (ARFs) 23 ′, 34 ) together and the occlusion in the patient's mouth while FIGS. 15C and 15D show side views, respectively, of the upper and lower processed arches (held in arch reconstruction frames (ARFs) 23 ′, 34 ) together and the occlusion in the patient's mouth.
[0053] The separated teeth 11 ′ present in wax 33 , 33 ′ can now be moved progressively to obtain their desired position (aligned position) depending on the malocclusion and as required by the treating doctor.
[0054] As shown in FIGS. 16 and 17 , thin layer of a good insulating material 37 , i.e., a thermo-resistant material (e.g., alginate or silicone material), which melts at a higher temperature than wax 33 , is placed on the top and bottom exposed surfaces of wax 33 present in arch reconstruction frame (ARF) 23 ′. This will prevent the heat from reaching the wax 33 directly that can melt the whole wax layer especially wax present around the neighboring teeth. If the insulating layer is placed on one surface then it is named as “double layer technique” and if on both the surfaces then it is named as “triple layer technique” as shown in FIG. 17 .
[0055] In order to keep a digital picture record of the progressive movements of tooth/teeth, a Digital Picture Recorder (DPR) is used. As shown in FIGS. 18A , 18 B and 19 , the Digital picture Recorder (DPR) 39 has a platform 40 , which supports arch reconstruction frames (ARFs) 23 ′, 34 and one or more cameras 41 a , 41 b , 41 c and 41 d . The arch reconstruction frames (ARFs) 23 ′, 34 and one of the cameras 41 a are supported on a vertical bars platform 42 . As better shown in FIG. 19 , vertical bars platform 42 includes a plurality of magnets 43 that correspond in location to the balls 26 on the arch reconstruction frames (ARFs) 23 ′, 34 . This magnet/ball system 43 , 26 will allow the arch reconstruction frames (ARFs) 23 ′, 34 to be placed at the same position every time. Bars 30 ′, 30 ′ also provide for alignment of the arch reconstruction frames (ARFs) 23 ′, 34 using holes 25 in the arch reconstruction frames (ARFs) 23 ′, 34 , as shown in FIGS. 19 and 20 . Digital cameras 41 a , 41 b , 41 c and 41 d are placed all around the platform 40 to take the pictures from different perspective angles/views as shown in FIG. 18A .
[0056] Before giving any movement to any tooth, an arch reconstruction frame (ARF) having a reconstructed arch is placed on the platform 42 of digital picture recorder (DPR) 39 as shown in FIG. 18B . Photographs are then taken with digital cameras 41 a , 41 b , 41 c and 41 d placed around the platform 40 to take the pictures from different perspective angles/views as shown in FIG. 18A and the photographs appropriately named, e.g., as “Picture#1.” As an alternative, a 3-D scanner can be used in place of digital cameras 41 a , 41 b , 41 c and 41 d . Scanning is performed to convert the existing physical data into digital data and named as Scan#1. The arch reconstruction frame (ARF) is then removed and desired tooth/teeth are moved using following process.
[0057] To move any tooth in a reconstructed arch, the insulating layer 37 is removed around that specific tooth. The arch reconstruction frame (ARF) containing that reconstructed arch is placed in a movement platform with heads 20 of the pins 19 exposed, e.g., facing downward. Depending upon the desired movement which can be in any one axis, a mechanical movement device is placed under that tooth in such a way that the pin's head 20 fits into the tooth fixture clamp/slot present in the mechanical movement device. Then it is locked to stabilize the whole assembly.
[0058] An example of a movement platform is shown in FIGS. 21A and 21B , which show, respectively, a side perspective view and a top perspective view of the movement platform 44 . The movement platform 44 shown in this example is a custom made device having a base 45 supported on legs 46 .
[0059] Vertical bars 47 , spaced a distance corresponding to the bars 30 of the vertical articulator 28 , are provided to be inserted through holes 25 of an arch reconstruction frame (ARF) to hold the arch reconstruction frame (ARF) containing a reconstructed arch in place. The base 45 has a U-shaped track 48 to guide an adjustment arm 49 on which a mechanical movement device can move. The adjustment arm 49 can be locked in a desired position in the U-shaped track 48 using a locking screw 50 .
[0060] Mechanical movement devices, generally designated by the reference numeral 51 (see FIGS. 22A and 22B ) are customized mechanical tools designed to move an individual tooth with its associated pin fixture in either direction along or around a single axis. There are at least four types of movement tools, including a:
i. rotational tool (for movement of tooth around long axis of its pin); ii. tipping tool (for movement of crown in one direction and of its pin in opposite direction); iii. translational tool (for bodily movement of tooth as a whole in linear plan); and iv. vertical correction tool (for downward/upward, i.e., intrusion/extrusion movement of tooth).
[0065] Each movement tool assembly has some basic parts which are common in all tools, although the principle design which determines the type of movement that a tool will produce varies in the different tools. In almost every tool there is a tooth fixture clamp/slot, generally designated by the reference numeral 52 , which will receive and snugly engage/receive the head 20 of the pin fixture 19 coming out of the tooth 11 ′. Every tool has a ball bearing joint with a rotational base that provides a freedom of adjustment to the tooth fixture clamp/slot 52 .
[0066] As shown in FIG. 22A , an arch reconstruction frame (ARF) 23 ′ is then slid along twin vertical bars 47 of the movement platform 44 . A mechanical movement device 51 is provided on the adjustment arm 49 and the adjustment arm 49 moved along U-shaped track 48 so that head 20 of the tooth desired to be moved is aligned with the tooth fixture clamp 52 of the movement tool 51 along the long axis of pin 19 fixed to tooth 11 ′. The adjustment arm 49 is locked in a desired position in the U-shaped track 48 using the locking screw 50 . After this visual adjustment of movement tool's passive components, the arch reconstruction frame (ARF) 23 ′ is slid down along the twin vertical bars 47 so that pin's head 20 (of tooth desired to be moved) fits in the tooth clamp/slot fixture 52 and it is tightened.
[0067] In this state, as shown in FIG. 22B , the pin 19 of the tooth 11 ′ desired to be moved has its corrugated portion 21 surrounded by wax 33 and its head 20 fitted/locked into the tooth clamp/slot fixture 52 of the mechanical movement device 51 . Heat is applied from heater 53 to the tooth fixture clamp/slot 52 of the mechanical movement device 51 , which softens the wax 33 around the corrugated portion 21 of the pin 19 (as heat is transferred to the pin 19 ). The thin layer of insulating material 37 surrounding other pins' heads 20 will prevent heat from melting unnecessary wax.
[0068] With the help of the mechanical movement device 51 , measured movement is applied to move the individual tooth into the desired direction in along or about one axis.
[0069] The wax 33 is again left for some time to cool down and then the mechanical device 51 is unlocked and removed. Upper and Lower arches are replaced in the vertical articulator and brought in close approximation with each other to check any inter-arch interferences etc.
[0070] The arch reconstruction frame (ARF) having the moved tooth/teeth is placed again on the platform 40 of a digital picture recorder (DPR) 39 and additional picture(s) taken again, e.g., named as “Picture#2.” The pictures can be loaded in software that has the ability to give following benefits:
to show the transition from one step to next step to see any unnecessary/unintentional movement of tooth/teeth to keep a digital picture record of the all the previous steps. Pictures taken by the above method can also be loaded in certain commercially available software for review.
[0073] Alternatively, in the case of using a 3-D scanner, the arch reconstruction frame (ARF) having the moved tooth/teeth is placed again on the platform of 3-D scanner and current position of teeth is scanned, to convert the physical data into digital data named as Scan#2. Digital data obtained is utilized later to show to the orthodontist. Print-outs of 3-D models from a 3-D printer can be utilized to make the tooth positioner.
[0074] The arch reconstruction frame (ARF), having moved tooth/teeth in a new position, is now placed inside the thermoforming machine to fabricate a tooth positioner on it. The top insulting layer will prevent the heat of thermoforming machine from melting unnecessary wax and will resist the air pressure as well. Tooth positioner is trimmed, finished and is worn by the patient for given time.
[0075] The same steps are repeated and next tooth positioner is made and worn by the patient till the time that desired position of tooth/teeth is achieved.
[0076] A diagnostic setup may be accomplished using the described tools and method, which is similar to the process described above and involves:
1.1. Zeroing
[0077] 1.2. Arch reconstruction
1.3. Establishing bite registration/occlusion
1.4. Taking picture #1 or scan#1
1.5. Mounting on the movement platform
1.6. Moving one or more tooth/teeth using different movement tools
1.7. Taking picture #2 or scan#2
The only differences from the process for making the tooth positioner described above is that optionally the type of casting material used can differ (less expensive casting materials such as plaster can be used in this diagnostic setup process), the amount of movement which is given through the movement devices (the cast tooth/teeth is/are moved to the desired positions) and, as this is a diagnostic setup for review only, no tooth positioner is made. Rather, the pictures can be uploaded in a flash based software program which morphs the two pictures so that they can be reviewed to see if the goals set by the treating doctor/orthodontist are achieved, keeping in mind all the basic principles of orthodontics.
[0078] Examples of mechanical movement devices are shown in FIGS. 23A-23F .
[0079] FIG. 23A shows an example of the rotational mechanical movement device 51 a . The rotational mechanical movement device 51 a includes a sliding base 54 a into which the adjustment arm 49 of the movement platform 44 is inserted. A ball bearing joint 55 a helps the tooth fixture clamp 52 a to align in the same axis as that of the head 20 of the pin 19 and its associated tooth 11 ′. The ball bearing joint 55 a is locked with the help of locking key 56 a . The clamp adjustment wheel 57 a is used to tighten the tooth fixture clamp 52 a around a head 20 of a pin 19 . The rotational base 58 is rotatable about a longitudinal axis of the tooth fixture clamp 52 a and the rotational base 58 in the direction of the arrows 59 a or 59 a ′. A gauge wheel 60 is provided to help to determine the amount of movement given. A connecting rod 61 connects the gauge wheel 60 to the ball bearing joint 55 a and a connecting bar 62 connects the tooth fixture clamp 52 a to the rotational base 58 . A screw 67 is provided for easy handling of the device. Rotating the rotational base 58 and the tooth fixture clamp 52 a about their longitudinal axis in the direction of the arrows 59 a or 59 a ′ gives rotational movement to a cast tooth 11 ′.
[0080] FIGS. 23B and 23C show an example of a tipping mechanical movement device 51 b . The tipping mechanical movement device 51 b includes a sliding base 54 b into which the adjustment arm 49 of the movement platform 44 is inserted. Thus, sliding base 54 b is fixed in position with respect to the base 45 by being fixed to adjustment arm 49 in U-shaped track 48 with the help of locking screw 50 . A tooth fixture slot element 52 b is shaped to receive, in slots provided on two opposite sides thereof, the head 20 of the pin 19 of the associated tooth 11 ′ that is to be moved. The slots of the tooth fixture slot element 52 b do not enclose pin's head 20 ; rather each slot just pushes the pin's head 20 in any given direction to generate a rotational movement in which crown 17 and pin's head 20 move in opposite directions. The tooth fixture slot element 52 b is attached to a sliding platform 64 b by a primary engaging bar 65 b . When gauged handle 63 b is rotated it will move the sliding platform 64 b in linear direction along and with respect to the sliding base 54 b through action of mechanism 66 b . Movement given to the sliding platform 64 b will be transferred in the primary engaging bar 65 b and tooth fixture slot element 52 b as they are attached with the sliding platform 64 b . This will push the head 20 of the pin 19 in one direction with out any counter acting force at the opposing end, causing the crown 17 and pin's head 20 to move in opposite directions as shown by arrows 59 b , 59 b ′. Measurement present on the gauged handle 63 b will enable to determine the extent of movement. Of course, as shown in FIG. 23C , by using the slot on the opposite side from that shown being used in FIG. 23B , the crown 17 and head 20 can be made to move in opposite directions (shown by arrows 59 b , 59 b ′) opposite to those in FIG. 23B .
[0081] FIG. 23D shows an example of a translational mechanical movement device 51 d . The translational mechanical movement device 51 d includes a sliding base 54 d into which the adjustment arm 49 of the movement platform 44 is inserted. A tooth fixture clamp 52 d receives and clamps the head 20 of the pin 19 of the associated tooth 11 ′ that is to be moved. The clamp adjustment wheel 57 d is used to tighten the tooth fixture clamp 52 d around a head 20 of a pin 19 . The tooth fixture clamp 52 d is attached to a sliding platform 64 d by primary engaging bar 65 d and a ball bearing joint 55 d . When gauged handle 63 d is rotated it will move the sliding platform 64 d in linear direction along the sliding base 54 d through action of mechanism 66 d . Movement given to the sliding platform 64 d will be transferred in the primary engaging bar 65 d and tooth fixture clamp 52 d as they are attached with the sliding platform 64 d . Since the tooth fixture clamp 52 d is locked with the help of clamp adjustment wheel 57 d , the whole pin 19 is translated along with the tooth 11 ′ in the direction of arrows 59 d and 59 d ′. A pillar 68 is fixed on top surface of the sliding platform 64 d . A connector 69 with U-shaped hook 70 can be placed into a slot in a vertical adjustable holder 71 with locking screw 72 present on the pillar 68 , which is adjustable vertically. The length of connector 69 can also be changed horizontally to reach to the neck part 22 ″ of the post 19 . Once the whole assembly is locked, connector 68 with a U-shaped hook 70 at its end is placed in the neck part 22 ′ of the pin 19 . This will help to achieve the movement of pin 19 and tooth 11 ′ as a whole in the same direction. The translational mechanical movement device 51 d can be used without this connector 69 , but without connector 69 there may be a possibility that the cast tooth 11 ′ will lag behind the head 20 of pin 19 which is firmly gripped in the pin fixture clamp 52 d . Measurement present on the gauged handle 63 d will enable to determine the extent of movement.
[0082] FIG. 23E shows two different connectors 69 ′, 69 ″ for the translational mechanical movement device 51 d shown in FIG. 23D . Each connector 69 ′, 69 ″ includes a U-shaped hook 70 ′, 70 ″, the connector 69 ′, 69 ″being chosen according to the direction of movement desired as shown by the arrows.
[0083] FIG. 23F shows an example of a vertical correction mechanical movement device 51 f . The vertical correction mechanical movement device 51 f includes a sliding base 54 f into which the adjustment arm 49 of the movement platform 44 is inserted. A tooth fixture clamp 52 f receives and clamps the head 20 of the pin 19 of the associated tooth 11 ′ that is to be moved. Ball bearing joint 55 f will help the tooth fixture clamp 52 f to align in the same axis as that of the pin fixture 19 and its associated tooth 11 ′. Ball bearing joint 55 f is locked with the help of its locking key 56 f . The head 20 is tightened and locked in the tooth fixture clamp 52 f with the clamp adjustment wheel 57 f . When gauged handle 63 f is rotated (clockwise/anti-clockwise) it will move the sliding cylinder 65 f in downward/upward direction by a mechanism (not shown). Since the tooth fixture clamp 52 f is locked with on the head 20 , the whole pin 19 is translated along with the tooth 11 ′ downwards or upwards as shown by the arrow 59 f . Measurement present on the gauged handle 63 f will enable to determine the extent of movement.
[0084] The present invention provides an improved way to replicate the initial position of the patient's dentition without any chances of adding any error. It also provides an accurate and precise movement to a tooth in an intended direction using mechanical devices capable of moving tooth in a measured manner in at least one direction in or about only one axis. Such movements combined over a number of tooth positioners manufactured following movements given through mechanical devices will correct malocclusion as planned. Another improvement in the present invention is addition of two insulating layers around the thermoplastic layer (which holds the teeth) which provides insulation and stability to the setup at initial and during the course of treatment. The present invention also provides a provision of digital visualization of the patient's dentition using initial images of the patient's dentition from different perspectives and images during and at the proposed end of treatment from different perspectives, morphing these to show the transition of treatment and proposed final correction of malocclusion. This gives the treating practitioner and patient an opportunity to view, change or accept the proposed treatment outcome before it is incorporated in the active appliance.
[0085] While the accompanying figure shows and this description describe some embodiments of the invention, the invention is not limited thereto. One skilled in the art will understand that numerous variations and modifications are possible without departing from the spirit and scope of the invention defined by the following claim(s). | A method and apparatus form a tooth positioner for repositioning at least one tooth of a patient and provide a dental arch cast of a patient, separate at least one tooth from the dental arch cast, fix a pin in a stump part of the at least one separated tooth, and in any non-separated teeth, reconstruct the dental arch cast of the patient by aligning the separated teeth to correspond to the alignment in the patient's mouth and hold the pins in a material that may be softened, soften the material, apply force to the pin fixed in the at least one tooth to be repositioned to move it in a desired direction to obtain a realigned arch, and form a tooth positioner corresponding to the realigned arch. The tooth positioner is used by having the patient wear it for a period of time. | 8 |
CROSS-REFERENCE TO RELATED APPLICATION
[0001] The present document is based on and claims priority to U.S. Provisional Application Ser. No. 61/356,442, filed Jun. 18, 2010, incorporated herein by reference.
BACKGROUND
[0002] Rotary steerable drilling systems for drilling deviated boreholes into the earth are generally classified either as point-the-bit systems or push-the-bit systems. In point-the-bit systems, the axis of rotation of the drill bit is deviated from the local axis of the bottom hole assembly in the general direction of the new portion of the hole being drilled. The borehole is propagated according to customary three-point geometry defined by upper and lower stabilizer touch points and the drill bit. The angle of deviation of the drill bit axis coupled with a finite distance between the drill bit and a lower stabilizer results in a non-collinear condition required for a curve to be generated. In this type of system, the drill bit tends to have less sideways cutting because the bit axis is continually rotated in the direction of the curved borehole.
[0003] In push-the-bit rotary steerable systems, there is usually no specially identified mechanism to deviate the bit axis from the local bottom hole assembly axis. Instead, the requisite non-collinear condition is achieved when either upper or lower stabilizers are used to apply an eccentric force or displacement in a direction oriented with respect to the direction of borehole propagation. Steering is again achieved by creating non co-linearity between the drill bit and at least two other touch points. In this type of system, the drill bit is required to cut sideways to generate the desired, curved borehole.
[0004] In many of these rotary steerable systems, pistons may be used to create force against a borehole wall or to cause angular displacement of one steerable system component with respect to another to cause the drill bit to move in the desired direction of deviation. The pistons are deployed in a piston actuated mechanism and forced to their desired displacement to achieve the directional control. The pistons are manipulated via drilling mud pumped down through the bottom hole assembly. However, such systems may be subjected to internal wear from the flowing mud and also may be limited with respect to the forces which may be applied to steer the drill bit.
SUMMARY
[0005] In general, the present invention provides a technique which facilitates steering of steerable systems when conducting directional drilling operations. A directional drilling system (e.g. a rotary steerable system) is preferably combined with a pressurized oil system which delivers oil to a piston actuated mechanism. The pressurized oil provides precise, long-lasting control over the orientation of the bottom hole assembly and the drill bit to facilitate directional drilling of boreholes through subterranean formations.
BRIEF DESCRIPTION OF THE DRAWINGS
[0006] Certain embodiments of the invention will hereafter be described with reference to the accompanying drawings, wherein like reference numerals denote like elements, and:
[0007] FIG. 1 is a schematic illustration of a rotary steerable system coupled with a pressurized oil system, according to an embodiment of the present invention; and
[0008] FIG. 2 is a schematic example of one type of bottom hole assembly and rotary steerable system incorporating pistons which are controlled by the pressurized oil system, according to an embodiment of the present invention.
DETAILED DESCRIPTION
[0009] In the following description, numerous details are set forth to provide an understanding of the present invention. However, it will be understood by those of ordinary skill in the art that the present invention may be practiced without these details and that numerous variations or modifications from the described embodiments may be possible.
[0010] The disclosure herein generally relates to a steering system for directional drilling. A bottom hole assembly incorporates a rotary steerable system having a piston actuated mechanism. However, the piston actuated mechanism is controlled by pressurized oil supplied from a pressurized oil system rather than being controlled by flowing drilling mud. The flow of oil to pistons of the piston actuated mechanism is controlled by a valve system. The valve system allows the pressurized oil to be ported to the pistons of the rotary steerable system to, for example, point the bit in the desired steering direction. The force required to manage the reactive forces from weight on bit (WOB), bottom hole assembly (BHA) mass and other drilling loads is provided by the pressure differential between the annulus and the pressurized oil acting across the piston area of the pistons. The separate pressurized oil system may be used with, for example, point-the-bit type systems, push-the-bit systems, or other types of steerable drilling systems.
[0011] Referring generally to FIG. 1 , an embodiment of a drilling system 20 is illustrated. In this embodiment, drilling system 20 comprises a bottom hole assembly 22 coupled with a pressurized oil system 24 . The bottom hole assembly 22 comprises a drill bit 26 connected to a rotary steerable system 28 having a steering section 30 which is selectively manipulated via a piston actuated mechanism 32 having a plurality of pistons 34 . Pressurized oil system 24 is employed to route pressurized oil to piston actuated mechanism 32 and to selected pistons 34 via oil supply lines 36 . The pressurized oil is used to move specific pistons 34 which changes the orientation of the drill bit 26 , e.g. changes the drilling axis orientation, with respect to the longitudinal axis 38 of the bottom hole assembly 22 . For example, the pistons 34 may be employed to control at least one of the directional bias and the axial orientation of the drill bit 26 . The pistons 34 may be arranged, for example, to point the drill bit 26 or to push the drill bit 26 . By way of specific example, the drilling system 20 utilizes rotary steerable system 28 which rotates with the plurality of pistons/actuators 34 . Additionally, the rotary steerable system 28 may be used in conjunction with stabilizers, such as non-rotating stabilizers.
[0012] Pressurized oil system 24 may comprise an oil pump 40 which pressurizes the oil supplied through oil supply lines 36 for controlling the drilling orientation of the rotary steerable system 28 . The pressurized oil from pump 40 may be routed through a valve system 42 used to control the flow and pressure of the oil supplied to pistons 34 of rotary steerable system 28 and piston actuated mechanism 32 .
[0013] In the embodiment illustrated, oil pump 40 is driven by a shaft 44 which, in turn, may be driven directly by flowing drilling mud flowing through a turbine 46 or other device designed to power oil pump 40 . Alternatively, the oil pump 40 may be powered by an electric motor 48 . In the case of an electric motor, electrical power may be provided to motor 48 by an alternator 50 . By way of example, the alternator 50 may be driven by drilling mud, e.g. driven by drilling mud via a mud turbine or mud pump (PDM) 52 . In the embodiment employing electric motor 44 , a speed control system 54 may be implemented to maintain a constant pump pressure. In the embodiment in which pump 40 is a direct mud driven pump, the pressure may be maintained by an internal pressure relief valve 56 . It should be noted that electrical power may be supplied to motor 48 from other sources, e.g. from a surface supply coupled to electric motor 48 via cable or other conductors routed downhole.
[0014] The motive fluid for steering rotary steerable system 28 , e.g. oil supplied through oil supply lines 36 , works between a high-pressure source and a low-pressure reservoir. The low-pressure reservoir may be pressure balanced with the pressure internal to the drill string. The power required to provide the cyclic steering forces as the drill string rotates often requires a mechanical source of energy of several kWatts. For example, 5000 pounds acting over 0.25 square inches requires 141 joules at four times a second (240 rpm)−mechanical power of 1700 Watts assuming there is no energy recycling/storage.
[0015] The valve system 42 employs valves to control the flow of pressurized oil into/out of the pistons 34 , and those valves may comprise bistable actuators (low energy fluid flow switches) or piezo restrictive actuator valves. As an alternative, the valve system 42 may employ a rotary valve format, such as the rotary valve format used in the PowerDrive rotary steerable system available from Schlumberger Corporation. In either case, the system is designed to track the local gravity vector to enable the system to determine which valves are to be activated to achieve the required steering response taking into account the various tool face offset effects that exist due to friction, bit response, bottom hole assembly load, formation tendencies, and other potential factors. The gravity and valve data may be provided by suitable sensors. However, other types of valves and sensor systems may be employed in pressurized oil system 24 to control the flow of pressurized oil.
[0016] By using the separate pressurized oil system 24 to control the orientation of rotary steerable system 28 , less internal wear results which enables extended runtimes and a reduction in tools for each drilling job. The pressurized oil system also is amenable to higher pressure which, in turn, enables actuation by smaller pistons 34 , thereby providing more flexibility with respect to both packaging and actuation. The pressurized oil system 24 further enables use of higher forces while eliminating the coupling of actuation force and flow rate of the drilling mud. Additionally, the system 20 no longer requires relatively high bit drop pressures. The pressurized oil also can be combined with oil needed for other drilling systems. Depending on the specific application, the pressurized oil system 24 may be located in whole or in part downhole along the drill string. For example, the oil pump 40 and the valve system 42 may be located anywhere in the bottom hole assembly. The rotary steerable system 28 and the pressurized oil system are designed so that the pistons 34 can be actuated independently to achieve a straight ahead steering. Additionally, the design of the system enables modulation of the piston displacement and forces in synchronism with the phase of drill string rotation to achieve intermediate steering curvatures.
[0017] The pressurized oil system 24 may be used in combination with a variety of bottom hole assemblies 22 and rotary steerable systems 28 . However, one example of a suitable bottom hole assembly is illustrated in FIG. 2 . A similar bottom hole assembly is described in U.S. Pat. No. 7,188,685. In this example, bottom hole assembly 22 combines both point-the-bit and push-the-bit technologies. It should be noted, however, the pressurized oil system 24 may be combined with a variety of other types of steerable bottom hole assemblies for use in directional drilling. For example, the rotary steerable system 28 may be a purely point-the-bit system or a purely push-the-bit system.
[0018] In the example illustrated, bottom hole assembly 22 comprises an upper stabilizer 58 mounted on a collar 60 which may be positioned adjacent rotary steerable system 28 . A lower stabilizer 62 is attached to an upper section 64 of rotary steerable system 28 . A steering section 65 is connected to drill bit 26 . A surface control system 66 may be utilized to communicate steering commands to electronics in upper section 64 . In some embodiments, the rotary steerable system 28 rotates with the pistons/actuators 34 and the stabilizers 58 and/or 62 may comprise non-rotating stabilizers.
[0019] The drill bit 26 is tilted about a swivel 67 which may be in the form of a universal joint 68 . In this embodiment, the steering section 65 is selectively actuated (e.g. pivoted/rotated) about swivel 67 with respect to upper section 64 to actively maintain a bit axis 69 pointing in a particular direction while the bottom hole assembly is rotated at a desired rotational speed of the drill string. Pistons 34 act on a periphery of the steering section 65 to apply a force for tilting the drill bit 26 with respect to the bottom hole assembly or tool axis 38 . The direction or orientation of the drill bit 26 broadly defines the direction of borehole formation. In a push-the-bit type system, the pistons 34 can be configured to act against the surrounding wellbore wall.
[0020] In one example, pistons 34 are sequentially actuated by virtue of the pressurized oil from oil system 24 as steering section 65 pivots/rotates. This enables the desired tilt of the drill bit 26 to be actively maintained to ensure drilling in a desired direction through the formation. In other embodiments and situations, the pistons 34 may be intermittently actuated in a random manner by the pressurized oil supplied through oil supply lines 36 to, for example, drill straight ahead as discussed above. In still other embodiments and situations, the pressurized oil from oil system 24 is used to actuate pistons 34 in a directionally-weighted semi-random manner to provide for less aggressive steering as the steering section 65 pivots/rotates. In some situations, the pressurized oil system 24 may be used to activate either all or none of the pistons 34 simultaneously to lock the steering sleeve, e.g. steering section 65 , in a drill ahead configuration and/or to reduce wear on the steering actuators. A variety of methods may be employed to measure the sleeve angle so as to improve control over the toolface and to improve control over the direction in which the sleeve is oriented. As described above, the steering may be achieved by synchronously modulating the pistons 34 in both force and displacement in phase relationship with the desired toolface pointing direction. Accordingly, the pressurized oil system 24 provides great flexibility for controlling directional drilling in a variety of applications and with many types of bottom hole assemblies 22 and rotary steerable systems 28 .
[0021] Although only a few embodiments of the present invention have been described in detail above, those of ordinary skill in the art will readily appreciate that many modifications are possible without materially departing from the teachings of this invention. Accordingly, such modifications are intended to be included within the scope of this invention as defined in the claims. | A technique facilitates steering of rotary steerable systems when conducting directional drilling operations. A rotary steerable system is combined with a pressurized oil system which delivers oil to a piston actuated mechanism. The pressurized oil provides precise, long-lasting control over the orientation of the bottom hole assembly and the drill bit to facilitate directional drilling of boreholes through subterranean formations. | 4 |
TECHNICAL FIELD
[0001] The invention generally relates to a wheel assembly for a vehicle, and more specifically to a damper assembly for damping vertical movement of the wheel assembly.
BACKGROUND
[0002] Vehicular wheel assemblies are generally rotatably supported by and attached to a knuckle. The knuckle is pivotably attached to a frame of a vehicle. Other suspension components, such as a lower control arm, may also connect the knuckle to the frame, and are pivotably moveable relative to the frame and with the knuckle to accommodate vertical travel of the wheel assembly during operation. A primary damper, i.e., a shock absorber, typically interconnects one of the knuckle or the control arm to the frame and operates to attenuate vertical travel of the knuckle and the control arm. In addition to the shock absorber, a wheel damper assembly may be attached to the knuckle to further attenuate vertical vibration and/or movement of the wheel assembly.
SUMMARY
[0003] A damper assembly for damping movement of a damper mass is provided. The damper assembly includes a rod that extends along a longitudinal axis between a first end and a second end. A casing is disposed annularly about and in sealing engagement with the rod. The casing defines a primary fluid chamber between an interior surface of the casing and the rod. A piston is fixedly attached to the rod. The piston is disposed within and divides the primary fluid chamber. The rod includes an annular wall that extends along the longitudinal axis. The annular wall defines a first expansion chamber that also extends along the longitudinal axis. The rod further defines a first expansion port that extends radially through the annular wall of the rod. The first expansion port connects the first expansion chamber and the primary fluid chamber in fluid communication.
[0004] A suspension system for a vehicle is also provided. The suspension system includes a knuckle, a wheel assembly rotatably supported by the knuckle, and a damper assembly coupled to the knuckle. The damper assembly is configured for damping vertical movement of the wheel assembly. The damper assembly includes a rod. The rod extends along a longitudinal axis between a first end and a second end. Each of the first end and the second end of the rod are fixedly attached to the knuckle. A casing is disposed annularly about and in sealing engagement with the rod. The casing defines a primary fluid chamber between an interior surface of the casing and the rod. A fluid is disposed within the primary fluid chamber. The casing is moveable relative to the rod along the longitudinal axis. A mass is attached to and moveable with the casing. A first spring is coupled to the rod. The first spring is configured for opposing movement of the casing and the mass relative to the rod in a first direction along the longitudinal axis. A second spring is coupled to the rod. The second spring is configured for opposing movement of the casing and the mass in a second direction along the longitudinal axis. The first direction is opposite the second direction. A piston is fixedly attached to the rod. The piston is disposed within and divides the primary fluid chamber to define a first portion of the primary fluid chamber and a second portion of the primary fluid chamber. The piston includes at least one fluid passage extending therethrough along the longitudinal axis. The fluid passage connects the first portion and the second portion of the primary fluid chamber in fluid communication. The rod includes an annular wall that extends along the longitudinal axis. The annular wall defines a first expansion chamber and a second expansion chamber. The first expansion chamber extends along the longitudinal axis between the first end of the rod and the piston. The second expansion chamber extends along the longitudinal axis between the second end of the rod and the piston. The rod defines a first expansion port and a second expansion port. The first expansion port extends radially through the annular wall of the rod to connect the first expansion chamber and the first portion of the primary fluid chamber in fluid communication. The second expansion port extends radially through the annular wall of the rod to connect the second expansion chamber and the second portion of the primary fluid chamber in fluid communication. A first pressurized gas device is disposed within the first expansion chamber. The first pressurized gas device is compressible in response to an increase in pressure within the first expansion chamber. A second pressurized gas device is disposed within the second expansion chamber. The second pressurized gas device is compressible in response to an increase in pressure within the second expansion chamber.
[0005] Accordingly, as the fluid within the primary fluid chamber expands, due to an increase in temperature for example, the fluid may flow through the first expansion port and/or the second expansion port into the first expansion chamber and/or the second expansion chamber respectively, thereby allowing the expansion of the fluid without damaging the first and/or second cap bearing seal and leaking from the primary fluid chamber. The pressurized air devices within the first expansion chamber and the second expansion chamber provide a compressible cushion to allow the fluid to expand.
[0006] The above features and advantages and other features and advantages of the present invention are readily apparent from the following detailed description of the best modes for carrying out the invention when taken in connection with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0007] FIG. 1 is a schematic perspective view of a suspension system for a vehicle.
[0008] FIG. 2 is a schematic cross sectional view of a damper assembly.
[0009] FIG. 3 is a schematic cross sectional view of an alternative embodiment of the damper assembly.
DETAILED DESCRIPTION
[0010] Those having ordinary skill in the art will recognize that terms such as “above,” “below,” “upward,” “downward,” “top,” “bottom,” etc., are used descriptively for the figures, and do not represent limitations on the scope of the invention, as defined by the appended claims.
[0011] Referring to the Figures, wherein like numerals indicate like parts throughout the several views, a suspension system is generally shown at 20 . The suspension system 20 is for a vehicle (not shown). Referring to FIG. 1 , the suspension system 20 includes a knuckle 22 that rotatably supports a wheel assembly 24 relative to a frame (not shown) of the vehicle. The knuckle 22 is rotatably attached to the frame for rotation about a first axis 26 . A control arm 28 includes a ball joint 29 that pivotably attaches the control arm 28 to the knuckle 22 . The control arm 28 is rotatably attached to the frame for rotation about a second axis 30 . The control arm 28 supports the knuckle 22 relative to the frame, and cooperates with the knuckle 22 to allow vertical movement of the wheel assembly 24 relative to the frame. The wheel assembly 24 is rotatably attached to the knuckle 22 in any suitable manner, and may include but is not limited to a spindle (not shown), a brake rotor 32 and a brake caliper 34 . A tie rod 36 may be attached to the knuckle 22 and connected to a steering system (not shown) of the vehicle. It should be appreciated that the suspension system 20 shown in FIG. 1 is exemplary, and that the knuckle 22 , control arm 28 and the wheel assembly 24 may be shaped, sized and/or configured in some other manner not shown or described herein.
[0012] The suspension system 20 further includes a damping system 38 coupled to the knuckle 22 . The damping system 38 includes a damper mass 40 and a damper assembly 42 . The damper assembly 42 is configured for damping vertical movement of the damper mass 40 , and thereby for damping vertical movement and/or vibration of the wheel assembly 24 .
[0013] Referring also to FIG. 2 , the damper assembly 42 includes a rod 44 . The rod 44 extends along a longitudinal axis 46 between a first end 48 and a second end 50 . The rod 44 is attached to the knuckle 22 at each of the first end 48 and the second end 50 . The rod 44 and the longitudinal axis 46 thereof are disposed in a generally vertical orientation.
[0014] A casing 52 is disposed annularly about and in sealing engagement with the rod 44 . The casing 52 is moveable relative to the rod 44 along the longitudinal axis 46 . The casing 52 defines a primary fluid chamber 54 between an interior surface 56 of the casing 52 and the rod 44 . The casing 52 includes a first cap bearing seal 58 and a second cap bearing seal 60 . The first cap bearing seal 58 is disposed approximate, i.e., near, the first end 48 of the rod 44 . The first cap bearing seal 58 is configured for slideably supporting and sealing the casing 52 relative to the rod 44 . The second cap bearing seal 60 is disposed approximate, i.e., near, the second end 50 of the rod 44 . The second cap bearing seal 60 is also configured for slideably supporting and sealing the casing 52 relative to the rod 44 . The first cap bearing seal 58 and the second cap bearing seal 60 may include any sealing and bearing components necessary to seal the primary fluid chamber 54 relative to the rod 44 and moveably support the casing 52 relative to the rod 44 . A fluid 62 is disposed within the primary fluid chamber 54 . The fluid 62 may include but is not limited to a high viscosity oil suitable for damping movement between two components.
[0015] The damper mass 40 is attached to and moveable with the casing 52 . The damper mass 40 may be attached to the casing 52 in any suitable manner. The damper mass 40 may include any suitable weight sufficient to offset vertical movement of the wheel assembly 24 . For example, the damper mass 40 may include but is not limited to a weight of approximately 35 Kg. However, the weight of the damper mass 40 may vary for each different application. Vertical movement and/or vibration of the knuckle 22 imparts a vertical movement in the damper mass 40 , which transmits the vertical movement to the casing 52 . However, because the casing 52 and the damper mass 40 are moveable relative to the rod 44 , which supports the damper mass 40 and the casing 52 relative to the knuckle 22 , the damper mass 40 and the casing 52 may move vertically relative to the knuckle 22 . The damper assembly 42 dampens the vertical movement of the damper mass 40 and the casing 52 to reduce the vibration and/or vertical movement of the knuckle 22 , thereby improving driving performance and/or handling of the vehicle.
[0016] Referring to FIG. 2 , the damper assembly 42 includes a first spring 64 and a second spring 66 . The first spring 64 is coupled to the rod 44 near the first end 48 of the rod 44 . The first spring 64 is configured for opposing movement of the casing 52 relative to the rod 44 in a first direction along the longitudinal axis 46 . The first direction is generally indicated by direction arrow 68 . The second spring 66 is coupled to the rod 44 near the second end 50 of the rod 44 . The second spring 66 is configured for opposing movement of the casing 52 in a second direction along the longitudinal axis 46 . The second direction is generally indicated by direction arrow 70 . The first direction 68 is opposite the second direction 70 . Accordingly, when the damper mass 40 moves toward the first end 48 of the rod 44 , the first spring 64 resists the movement of the damper mass 40 and the casing 52 . Similarly, when the damper mass 40 moves toward the second end 50 of the rod 44 , the second spring 66 resists the movement of the damper mass 40 and the casing 52 . As shown in FIG. 2 , the first spring 64 and the second spring 66 may be disposed externally of and concentric with the casing 52 , i.e., outside the casing 52 . However, as shown in FIG. 3 , the first spring 64 and the second spring 66 may alternatively be disposed internally of and concentric with the casing 52 , i.e., inside the casing 52 within the primary fluid chamber 54 of the casing 52 .
[0017] A piston 72 is fixedly attached to the rod 44 . The piston 72 is disposed within and divides the primary fluid chamber 54 . The piston 72 divides the primary fluid chamber 54 to define a first portion 74 of the primary fluid chamber 54 and a second portion 76 of the primary fluid chamber 54 . The piston 72 includes at least one fluid passage 78 extending therethrough. The fluid passage 78 extends along the longitudinal axis 46 to connect the first portion 74 and the second portion 76 of the primary fluid chamber 54 in fluid communication. The fluid passage 78 may be configured in any suitable manner, and may include a valve (not shown) and/or other components capable of regulating the flow of the fluid 62 between the first portion 74 and the second portion 76 of the primary fluid chamber 54 . It should be appreciated that as the casing 52 moves toward the first end 48 of the rod 44 , the first portion 74 of the primary fluid chamber 54 increases in volume and the second portion 76 of the primary fluid chamber 54 decreases in volume. As this change in volume occurs, the fluid 62 is forced from the second portion 76 into the first portion 74 through the fluid passage 78 . Similarly, as the casing 52 moves toward the second end 50 of the rod 44 , the second portion 76 of the primary fluid chamber 54 increases in volume and the first portion 74 of the primary fluid chamber 54 decreases in volume. As this change in volume occurs, the fluid 62 is forced from the first portion 74 into the second portion 76 through the fluid passage 78 . The flow rate of the fluid 62 through the fluid passage 78 regulates the damping capacity of the damper assembly 42 .
[0018] The rod 44 includes an annular wall 80 . The annular wall 80 extends along the longitudinal axis 46 , and defines a first expansion chamber 82 and a second expansion chamber 84 . Both of the first expansion chamber 82 and the second expansion chamber 84 extend along the longitudinal axis 46 . The first expansion chamber 82 extends between the first end 48 of the rod 44 and the piston 72 . The second expansion chamber 84 extends between the second end 50 of the rod 44 and the piston 72 . The first expansion chamber 82 is generally disposed within the first portion 74 of the primary fluid chamber 54 , and the second expansion chamber 84 is generally disposed within the second portion 76 of the primary fluid chamber 54 . However, it should be appreciated that a portion of the first expansion chamber 82 and the second expansion chamber 84 may extend outward beyond the first portion 74 and the second portion 76 of the primary fluid chamber 54 respectively.
[0019] The annular wall 80 of the rod 44 further defines a first expansion port 86 and a second expansion port 88 . The first expansion port 86 extends radially through the annular wall 80 of the rod 44 to connect the first expansion chamber 82 and the primary fluid chamber 54 in fluid communication. The second expansion port 88 extends radially through the annular wall 80 of the rod 44 to connect the second expansion chamber 84 and the primary fluid chamber 54 in fluid communication. As shown in FIG. 2 , the first expansion port 86 connects the first portion 74 of the primary fluid chamber 54 and the first expansion chamber 82 in fluid communication, and the second expansion port 88 connects the second portion 76 of the primary fluid chamber 54 and the second expansion chamber 84 in fluid communication. However, as shown in FIG. 3 , the first expansion port 86 may alternatively connect the first portion 74 of the primary fluid chamber 54 and the second expansion chamber 84 in fluid communication, and the second expansion port 88 may alternatively connect the second portion 76 of the primary fluid chamber 54 and the first expansion chamber 82 in fluid communication.
[0020] A first pressurized gas device 90 is disposed within the first expansion chamber 82 , and a second pressurized gas device 92 is disposed within the second expansion chamber 84 . The first pressurized gas device 90 is compressible in response to an increase in pressure within the first expansion chamber 82 . The second pressurized gas device 92 is compressible in response to an increase in pressure within the second expansion chamber 84 . The first pressurized gas device 90 and the second pressurized gas device 92 may each include any suitable compressed gas device capable of compressing in response to an increase in fluid pressure of the fluid 62 and expanding in response to a decrease in fluid pressure of the fluid 62 , while maintaining separation between the compressed gas and the fluid 62 .
[0021] As the fluid 62 heats during use, the fluid pressure of the fluid 62 within the primary fluid chamber 54 increases. As the fluid pressure increases, the fluid 62 may seep into the first expansion chamber 82 and/or the second expansion chamber 84 through the first expansion port 86 and the second expansion port 88 , thereby compressing the first pressurized gas device 90 and/or the second pressurized gas device 92 . Accordingly, the first expansion chamber 82 and the second expansion chamber 84 act as an overflow chamber to accommodate expansion of the fluid 62 during use, thereby preventing damage to the first cap bearing seal 58 and/or the second cap bearing seal 60 , and leakage of the fluid 62 from the primary fluid chamber 54 . As the fluid 62 cools, thereby decreasing the fluid pressure, the first pressurized gas device 90 and/or the second pressurized gas device 92 may then expand, forcing the fluid 62 within the first expansion chamber 82 and the second expansion chamber 84 back into the first portion 74 and the second portion 76 of the primary fluid chamber 54 .
[0022] As shown in FIG. 2 , the first pressurized gas device 90 and the second pressurized gas device 92 may include any suitable device. For example, as shown in FIG. 2 , the first pressurized gas device 90 includes a first seal 94 moveably disposed within the first expansion chamber 82 . The first seal 94 divides the first expansion chamber 82 to define a first gas portion 96 and a first fluid portion 98 . The first seal 94 is configured for sealing between the first gas portion 96 and the first fluid portion 98 . The first pressurized gas device 90 further includes a valve 100 disposed at the first end 48 of the rod 44 , and configured for controlling a pressurized gas within the first gas portion 96 of the first expansion chamber 82 . The valve 100 may include but is not limited to a shcrader valve or other similar device. Accordingly, pressurized gas may be injected into the first gas portion 96 through the valve 100 to pressurize the first gas portion 96 between the valve 100 and the first seal 94 , thereby forming the first pressurized gas device 90 .
[0023] As shown in FIG. 2 , the second pressurized gas device 92 includes a second seal 102 moveably disposed within the second expansion chamber 84 . The second seal 102 divides the second expansion chamber 84 to define a second gas portion 104 and a second fluid portion 106 . The second seal 102 is configured for sealing between the second gas portion 104 and the second fluid portion 106 . The second pressurized gas device 92 further includes a valve 100 disposed at the second end 50 of the rod 44 , and configured for controlling a pressurized gas within the second gas portion 104 of the first expansion chamber 82 . The valve 100 may include but is not limited to a shcrader valve or other similar device. Accordingly, pressurized gas may be injected into the second gas portion 104 through the valve 100 to pressurize the second gas portion 104 between the valve 100 and the second seal 102 , thereby forming the second pressurized gas device 92 .
[0024] Referring to FIG. 3 , the first pressurized gas device 90 and the second pressurized gas device 92 are shown each including a plurality of pressurized gas filled spheres 108 . A first end plug 110 is disposed within the first expansion chamber 82 at the first end 48 of the rod 44 to seal the first expansion chamber 82 and secure the gas filled spheres 108 within the first expansion chamber 82 . A second end plug 112 is disposed within the second expansion chamber 84 at the second end 50 of the rod 44 to seal the second expansion chamber 84 and secure the gas filled spheres 108 within the second expansion chamber 84 . It should be appreciated that the first pressurized gas device 90 and the second pressurized gas device 92 may include other embodiments, including but not limited to gas filled flexible cylindrical tubes or some other similar structure.
[0025] While the best modes for carrying out the invention have been described in detail, those familiar with the art to which this invention relates will recognize various alternative designs and embodiments for practicing the invention within the scope of the appended claims. | A damper mass damper assembly includes a rod, and a casing disposed annularly about the rod and defining a primary fluid chamber therebetween. The rod includes an annular wall that defines a first and a second expansion chamber disposed at a first and a second end of the rod respectively. The rod further defines a first and a second expansion port connecting the first and the second expansion chambers respectively with the primary fluid chamber in fluid communication. As fluid within the primary fluid chamber expands from heating, the fluid may weep into the first and/or second expansion chambers through the first and/or second expansion ports respectively to maintain the integrity of a first and second cap bearing seal, which seal the fluid within the primary fluid chamber. | 5 |
CROSS-REFERENCES TO RELATED APPLICATIONS
This application is a continuation-in-part of U.S. application Ser. No. 09/553,234, filed Apr. 19, 2000, and issuing as U.S. patent Ser. No. 6,233,776 on May 22, 2001, U.S. application Ser. No. 09/553,234 is a continuation-in-part of U.S. application Ser. No. 09/418,752, filed Oct. 15, 1999 and now abandoned U.S. application Ser. No. 09/418,752 is a continuation-in-part of U.S. application Ser. No. 09/304,051, filed May 4, 1999, and issuing as U.S. patent Ser. No. 6,219,876 on Apr. 24, 2001. Each of the foregoing applications is incorporated in its entirety herein by reference.
FIELD OF THE INVENTION
The present invention relates to the field of cleaning, and, more particularly, to a device, method, and system for cleaning various surfaces.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention will be more readily understood through the following detailed description, with reference to the accompanying drawings, in which:
FIG. 1 is a side view of an exemplary embodiment of a rolling cleaning system 100 of the present invention;
FIGS. 2A-2D are side views of an exemplary selection of surfaces that can be cleaned using certain embodiments of the present invention;
FIG. 3 is a side view of an exemplary embodiment of a rolling cleaning system 300 of the present invention;
FIG. 4 is a side view of an exemplary embodiment of a rolling cleaning system 400 of the present invention;
FIG. 5 is a side view of an exemplary embodiment of a rolling cleaning system 500 of the present invention;
FIG. 6 is a side view of an exemplary embodiment of a rolling cleaning system 600 of the present invention;
FIG. 7 is a side view of an exemplary embodiment of a rolling cleaning system 700 of the present invention;
FIG. 8 is a side view of an exemplary embodiment of a rolling cleaning system 800 of the present invention;
FIG. 9 is a side view of an exemplary embodiment of a rolling cleaning system 900 of the present invention;
FIG. 10 is a side view of an exemplary embodiment of a rolling cleaning system 1000 of the present invention;
FIG. 11 is a side view of an exemplary embodiment of a rolling cleaning system 1100 of the present invention;
FIG. 12 is a side view of an exemplary embodiment of a rolling cleaning system 1200 of the present invention;
FIG. 13 is a side view of an exemplary embodiment of a rolling cleaning system 1300 of the present invention;
FIG. 14A is a side view of an exemplary embodiment of a rolling cleaning system 1400 of the present invention moving in a first direction;
FIG. 14B is a side view of an exemplary embodiment of a rolling cleaning system 1400 of the present invention reversing direction; and
FIG. 14C is a side view of an exemplary embodiment of a rolling cleaning system 1400 of the present invention moving in a second direction.
DETAILED DESCRIPTION
The present invention relates to cleaning various surfaces by employing a tacky surface or sheet on a series of rollers. Some known devices for cleaning surfaces, such as floors, utilize a single roll of perforated sheets having a tacky surface. One problem that arises with these devices is the repeated need for tearing or cutting away the tacky sheets once those sheets become soiled. Furthermore, removing the soiled sheets requires that the user's hands come in contact with the dirt and/or other debris attached to the tacky surface. Also, known tacky roll devices can not work effectively on many surfaces, such as thickly piled carpet, grooved wood floors, grout-separated tile floors, mortar-jointed brick floors, etc., because the known tacky roll devices have little, if any ability to penetrate cracks, crevasses, and deeper layers of carpet, etc.
FIG. 1 is a side view of an exemplary embodiment of a rolling cleaning system 100 of the present invention. Rolling cleaning system 100 can include two large internal rollers 105 , 110 for storing and/or dispensing a continuous long sheet 115 having at least one tacky surface. Tacky sheet 115 can be, by way of example only, plastic or paper coated with an acrylic based adhesive with sufficient tack as to be useful in removing dirt and/or debris from a variety of surfaces. The tack can range between any two integer values in the numerical range of 50 to 500 g/25 mm, with a preferred range of tack between 200 to 300 g/25 mm.
Tacky sheet 115 can be rolled across the floor or surface via four contact rollers 120 , 125 , 130 , 135 . These contact rollers can be constructed from, for example, plastic, rubber, foam rubber, and/or metal, etc. A take-up roller 140 can be used to create a space for the introduction of a brush 145 , and/or to remove slack from tacky sheet 115 . Brush 145 can have stiff bristles, which can be constructed from, for example, nylon, plastic, natural fiber, animal hair, and/or metal, etc. The height of brush 145 can be adjusted by raising or lowering handle 150 , which can be attached to shaft 155 , which can connect brush 145 to a housing 170 .
A large handle 160 can be used to push rolling cleaning system 100 across the floor or whatever surface is to be cleaned. Handle 160 can be pivotably, rotatably, and/or swivelably mounted on a pivot or pin 165 , in a manner well known in the art, to allow rolling cleaning system 100 to be pushed from either direction. By allowing rolling cleaning system 100 to be rolled in either direction, tacky sheet 115 can be dispensed or wound on either internal roller 105 , 110 depending upon the direction rolling cleaning system 100 is being pushed or pulled across the floor. Rolling cleaning system 100 can be at least partially surrounded by enclosure 170 , which can be constructed of, for example, plastic and/or metal.
Internal rollers 105 , 110 can be constructed of, for example, plastic and/or metal, and can be rotationally spring-loaded and/or clutched, e.g., akin to a window blind, to maintain tension in tacky sheet 115 and/or to facilitate the retrieval and/or advancement thereof. Tacky sheet 115 can be provided on, for example, one or two rollers sleeves (not shown) that can be placed onto or over one or both of internal rollers 105 , 110 . A roller sleeve can be constructed of, for example, cardboard, plastic, and/or metal. To avoid rotational slippage between the sleeve and the roller, the sleeves could be, for example, wider than the tacky sheet and secured to the roller with end caps, clamps or rubber bands.
After several uses, tacky sheet 115 can be completely wound back onto a roller sleeve and discarded. This can be accomplished by rolling the rolling cleaning system 100 in the same direction until tacky sheet 115 has completely spooled onto one roller sleeve. Also, this can be accomplished by way of a spring loaded auto advance (not shown) that can be manually activated. The auto-advance can be accomplished pushing a button on the handle or the base of the cleaning system that locks the roller with the sleeve that has the unused portion of the tacky sheet, at the same time this button would release the clamping force on the sleeve on this roller, allowing the sleeve to slip and rotate or slip around the roller (much like a roll of paper towels on a fixed post), as the spring forces in the opposing roller advances the tacky sheet forward and onto the unlocked roller. Further, advancing the adhesive sheet onto the roller sleeve can be accomplished by using an electric motor (not shown). The motor could be attached to one of the roller, preferable the roller without the unused reserve portion of tacky sheet. Again by pushing a button the roller with the tacky sheet would be locked, the clamp that holds the sleeve onto this roller would be released, allowing the sleeve to rotate or slip about the roller. The motor on the opposing roller would then turn this roller and advance the tacky sheet forward and onto the motorized roller. The roller sleeve could advance when the user, for example, pushes a button, turns a knob, and/or squeezes a lever, etc. The electric motor can receive power by either plugging the rolling cleaning system 100 into a power outlet, or by charging a battery to be used by the rolling cleaning system 100 .
FIG. 2 is a side view of an exemplary selection of surfaces that can be cleaned using certain embodiments of the present invention. Surface 200 represents a very smooth and/or flat surface, such as tightly-joined hardwood or marble flooring, certain types of vinyl flooring, smoothly painted drywall, or even smooth concrete. Such surfaces would most likely not require the brush 145 illustrated in FIG. 1 .
Surface 210 represents a much rougher surface, such as worn concrete, black top, or a heavily textured fabric. Such surfaces would likely be cleaned more effectively with the brush illustrated in FIG. 1 in the down position.
Surface 220 represents a grouted tile or brick flooring surface, or a grooved fabric such as corduroy, that would benefit from use of the brush to removed dirt and debris from the grooves or grout lines.
Surface 230 represents a carpeted or heavily napped surface that would also be cleaned more effectively with the brush in FIG. 1 in the down position. While these examples illustrate a wide range of surfaces, other surfaces may also be cleaned with the present invention, including, for example, any or nearly any type of flooring, wall, and/or ceiling surface, and/or any or nearly any type of fabric.
In situations where the fabric is part of a garment or small item of furniture, an embodiment of the present invention could be rather small, perhaps less than a few inches wide. In the case of cleaning floors, an embodiment of the present invention could be twelve or more inches wide. In industrial applications, an embodiment of the present invention can be several feet wide. For use outdoors, such as on concrete, asphalt, or artificial surfaces, e.g., Astroturf, an embodiment of the present invention can be up to many yards wide.
FIG. 3 is a side view of an exemplary embodiment of a rolling cleaning system 300 of the present invention. Instead of the brush shown in FIG. 1, a sponge 305 can be placed between internal rollers 310 , 315 . Shaft 320 can connect sponge 305 to the rest of the assembly and/or to the housing 307 , and can contain a tube 320 that feeds cleaning solution from a reservoir 325 into the sponge 305 . The action of sliding sponge 305 across the floor can draw the cleaning solution down tube 320 . Reservoir 325 can be attached to handle 330 and/or to the housing and can contain a cap 335 that can be removed to add cleaning solution and/or water to reservoir 325 .
Tacky sheet 340 can be coated with a tacky adhesive that is effective when wet, such as, for example, an adhesive selected from a group consisting of: natural rubber in the presence of a plasticizer mixed with a hydrocolloid gum, synthetic rubber in the presence of a plasticizer mixed with a hydrocolloid gum, or polymeric adhesives consisting of co-polymers of 2-amino ethyl ethacrylate, and n-butyl methacrylate.
Another possible adhesive system would include a single blended adhesive with wet and dry properties. One class of materials, for example, could include the blending of certain hydrocolloid gums (e.g., gaur gum, locust bean gum, etc.) with certain pressure sensitive adhesive systems to improve tack of the moistened adhesive. Since these materials have a large capacity for absorbing moisture, they should provide good wet adhesive or tackiness. Possible pressure sensitive adhesives include many synthetic and natural rubbers in the presence of plasticizers, such as, polyisobutylenes, natural rubber, silicone rubbers, acrylonitrile rubbers, polyurathane rubbers, butyl rubber elastomer, etc. Such mixtures can be further enhanced by the introduction of natural and artificial fibrous materials, such as wood cellulose, cotton, or Dacrun. The introduction of these fibrous materials helps to improve the cohesive forces of the adhesive system.
FIG. 4 is a side view of an exemplary embodiment of a rolling cleaning system 400 of the present invention. This embodiment is similar to the exemplary embodiments illustrated in FIG. 1 and FIG. 3, except that neither a brush nor a sponge is provided. Instead, in this exemplary embodiment, rolling cleaning system 400 can have a center roller 410 that serves as a means of removing slack in tacky sheet 420 as tacky sheet 420 slides across the surface or floor being cleaned. Such a device could be particularly useful on smooth surfaces. Further, rolling cleaning system 400 could be useful on non-smooth surfaces if rollers 430 , 440 , 450 , 460 are coated and/or constructed from a compressible foam rubber or other substance that would allow tacky sheet 420 to be pushed into crevices of an uneven surface, such as shown in element 210 of FIG. 2 .
FIG. 5 is a side view of an exemplary embodiment of a rolling cleaning system 500 of the present invention. In this embodiment, cleaning device 500 has a set of contact rollers 510 , 520 , 530 , 540 that allows the tacky sheet 550 to be rolled across the surface rather than slid across the surface as in the earlier embodiments. In some embodiments, contact rollers 510 , 520 , 530 , and/or 540 can be rotationally fixed, thereby serving as guides for tacky sheet 550 . In other embodiments, contact rollers 510 , 520 , 530 , and/or 540 can freely rotate. Such a roller action may improve the effectiveness of the tacky surface in its ability to lift dirt and/or debris from a surface. Brushes 560 , 570 , 580 are located between contact rollers 510 , 520 , 530 , 540 to loosen and/or remove debris that is on the surface and/or in cracks or crevices.
FIG. 6 is a side view of an exemplary embodiment of a rolling cleaning system 600 of the present invention. In this embodiment, instead of the brush shown in FIG. 5, a sponge 605 is placed between rollers 610 , 615 . The shaft 620 that connects sponge 605 to the rest of the assembly and/or to the housing 607 contains a tube and/or channel (not shown) that feeds and/or wicks cleaning solution from a reservoir 625 into sponge 605 . Alternatively, the action of sliding sponge 605 across the floor can draw the cleaning solution down the tube. Reservoir 625 is attached to the handle 630 and contains a cap 635 that can be removed to add cleaning solution and/or water to the reservoir. In this embodiment, tacky sheet 640 will be coated on at least its cleaning side with a tacky adhesive that is effective when wet, and possibly on the non-cleaning side with a waterproof or water resistant coating.
FIG. 7 is a side view of an exemplary embodiment of a rolling cleaning system 700 of the present invention. Rolling cleaning system 700 is similar in certain respects to rolling cleaning systems 500 and 600 of FIGS. 5 and 6 respectively, except that rolling cleaning system 700 does not include a brush or a sponge. Rolling cleaning system 700 has a set of contact rollers 710 , 720 , 730 , 740 that can assist in keeping tacky sheet 780 in contact with the surface to be cleaned, and can help with advancing tacky sheet 780 as rolling cleaning system 700 is moved across that surface. Several take-up rollers 750 , 760 , 770 , which can be spring-loaded in the up-down direction (as determined by the operation of system 700 on a floor), can provide a means of removing any slack that arises in tacky sheet 780 .
FIG. 8 is a side view of an exemplary embodiment of a rolling cleaning system 800 of the present invention. In this embodiment, contact rollers 810 , 820 850 , and 860 assist with keeping tacky sheet 830 in contact with the surface to be cleaned. External contact rollers 810 , 820 are smaller than internal contact rollers 850 , 860 , so that rolling cleaning system 800 can reach under counters and other places that would be hard to reach if all four contact rollers were the same size. Also, adjustable brush 840 can be located between internal contact rollers 850 , 860 .
FIG. 9 is a side view of an exemplary embodiment of a rolling cleaning system 900 of the present invention. In this cleaning device, a sponge 905 is placed between the two internal contact rollers 910 , 915 instead of the brush shown in FIG. 8 . Shaft 920 can connect sponge 905 to the rest of rolling cleaning system 900 . Cleaning solution can flow from reservoir 925 into sponge 905 via a fluidly-coupled channel or tube (not shown) in shaft 920 . The action of sliding sponge 905 across the surface to be cleaned can draw the cleaning solution down the tube. Reservoir 925 is attached to handle 930 and contains a cap 935 that can be removed to add cleaning solution or water to reservoir 925 .
FIG. 10 is a side view of an exemplary embodiment of a rolling cleaning system 1000 of the present invention. This embodiment is similar to those described in FIGS. 8 and 9. In this embodiment, cleaning device 1000 has smaller external contact rollers 1010 , 1020 on either end, but does not contain a brush or a sponge.
Although the embodiments described in FIGS. 1 through 10 contain multiple rollers in contact with the surface to be cleaned, fewer rollers are possible, in fact only one roller could be used in the simplest device. Thus, although not every possible combination of rollers, brushes, and sponges is illustrated herein, the general scope of the present invention includes such variations of the embodiments described herein.
FIG. 11 is a side view of an exemplary embodiment of a rolling cleaning system 1100 of the present invention. In this embodiment, the cleaning device 1100 contains a tacky sheet 1105 that can be advanced or dispensed from one of two sheet rollers 1110 , 1115 depending upon the direction in which the device is rolled across the surface. Tacky sheet 1105 can be held in contact with the surface to be cleaned by two external contact rollers 1120 , 1125 . Two brush rollers 1130 , 1135 are also attached to the base of the rolling cleaning device 1100 on either side of a collection pan 1140 . Brush rollers 1130 , 1135 can pick up dirt and/or debris from the surface. That dirt and/or debris can then attach itself to the tacky surface of sheet 1105 . Alternatively, or in combination, brush rollers 1130 , 1135 can drop the dirt and/or debris into collection pan 1140 .
Tacky sheet 1105 can be guided along a flat planar guide 1155 inside device 1100 by two small guide rollers 1145 , 1150 . As tacky sheet 1105 slides across guide 1155 , tacky sheet 1105 can come in contact with a sheet brush 1160 that can remove any large pieces of loosely attached debris, whereby that debris can be deposited on collection pan 1140 .
Device 1100 can have a handle 1165 , as in previous embodiments, which can be flipped about a pivot or pin 1170 to change the direction of the device. As in previously-described embodiments, certain components of device 1100 , such as rollers 1110 , 1115 , 1120 , 1125 , 1130 , 1135 , 1145 , and/or 1150 , tacky sheet 1105 , collection pan 1140 , and/or brush 1160 , can also be at least partially enclosed in a case, chassis, or housing 1175 made from, by way of example only, plastic or metal. External contact rollers 1120 , 1125 , and brush rollers 1130 , 1135 , can be constructed of plastic, rubber, or other suitable material.
FIG. 12 is a side view of an exemplary embodiment of a rolling cleaning system 1200 of the present invention, which is similar in certain respects to the embodiment illustrated in FIG. 11 . In this embodiment, however, device 1200 has two additional external contact rollers 1210 , 1220 instead of two brush rollers. External contact rollers 1210 , 1220 can allow more surface area of tacky sheet 1230 to come in contact with the surface to be cleaned at any given instant.
FIG. 13 is a side view of an exemplary embodiment of a rolling cleaning system 1300 of the present invention. Device 1300 has two external contact rollers 1305 , 1310 that can help move tacky sheet 1315 across the surface to be cleaned. Tacky sheet 1315 can be advanced onto or removed from one of the two larger sheet rollers 1320 , 1325 inside device 1300 , depending on the direction device 1300 is moving across the surface.
When device 1300 is moved in the direction of the arrow shown in FIG. 13, friction between tacky sheet 1315 and the surface to be cleaned causes tacky sheet 1315 to move opposite to the direction of the arrow. Friction between tacky sheet 1315 and drive roller 1330 causes drive roller 1330 to rotate in the clockwise direction. By virtue of the contact between drive roller 1330 and driven roller 1335 , driven roller 1335 rotates in the counter-clockwise direction. Since driven roller 1335 is in contact with sheet roller 1320 , this contact causes sheet roller 1320 to rotate in the clockwise direction which has the effect of pulling tacky sheet 1315 onto sheet roller 1320 . As the diameter of sheet roller 1320 increases due to the accumulation of tacky sheet 1315 therearound, driven roller 1335 stays in contact with sheet roller 1320 by pivoting further up into the housing. The continuous tacky sheet can be spooled onto sheet roller 1325 and off of sheet roller 1320 by reversing the direction device 1300 is moving across the floor. This is done by moving handle 1340 to the right and swiveling handle 1340 about a linkage 1345 that causes the drive roller 1330 and driven roller 1335 to pivot about a pivot point 1350 . When this happens the whole process is reversed and tacky sheet 1315 is now wound onto sheet roller 1325 .
FIGS. 14A, B, and C illustrate the advancement of material from one roller to the other.
In FIG. 14A, the rolling cleaning device 1400 is shown with most of the tacky sheet 1440 spooled up and onto the front roller 1420 , with very little tacky sheet spooled onto the rear roller 1430 . The handle 1410 is tilted to the left and the device is pushed across the surface to the right.
In FIG. 14B, the rolling cleaning device is shown after the device as been roller predominately to the right, and as a result most of the material has been advanced from the front roller 1420 to the rear roller 1430 . At this point the handle 1410 would be pivoted in the direction of the arrow in FIG. 14 B.
FIG. 14C now illustrates the rolling cleaning device with handle 1410 tilted to the right and the device ready to be rolled predominately in the opposite direction with what was the rear roller 1430 , now being the front roller, with most of the tacky sheet spooled up and onto it, and with what once was the front roller 1420 , now being the rear roller, with little if any tacky sheet spooled there upon.
Still other advantages and embodiments of the invention will become readily apparent to those skilled in this art from the above-recited detailed description and provided drawings. Accordingly, the drawings and descriptions are to be regarded as illustrative in nature, and not as restrictive. | A device is disclosed for cleaning a surface. In one embodiment, the device includes a sheet having at least one tacky surface and a plurality of rollers in contact with said sheet, said plurality of rollers, in an operative embodiment, maintaining contact between said tacky surface and the surface to be cleaned. | 6 |
FIELD OF THE INVENTION
[0001] The present invention relates generally to semiconductor integrated circuit processing, and more specifically to an improved method of forming a contact in an integrated circuit.
BACKGROUND OF THE INVENTION
[0002] As feature sizes and device sizes shrink for integrated circuits, relative alignment between interconnect layers becomes of critical importance. Misalignment can severely impact the functionality of a device. Misalignment beyond certain minimum tolerances can render a device partly or wholly inoperative.
[0003] To insure that contacts between interconnect layers are made properly even if a slight misalignment occurs during masking steps, extra space is usually included in a design around contacts and other conductive features. This extra retained space is known as enclosure and results in the well known “dogbone” structure. Enclosure sizes of up to a few tenths of a micron are typical for 0.5 to 1.0 micron feature sizes.
[0004] Enclosure requirements are not consistent with the continued shrinkage of devices. Enclosure is not related to device functionality, but is due primarily to limitations in photolithography alignment capability and is used to insure that misalignment errors do not cause problems with the device. When designing devices having minimum feature and device sizes, minimizing enclosure requirements can significantly impact the overall device size.
[0005] Self-alignment techniques are generally known in the art, and it is known that their use helps minimize enclosure requirements. However, the use of self-alignment techniques has been somewhat limited by device designs in current use.
[0006] Conventional MOS FET devices are typically comprised of a gate electrode overlying a channel region and separated therefrom by a gate oxide. Conductive regions are formed in the substrate on either side of the gate electrode and the associated channel to form the source and drain regions. However, the majority of the area required for the source and drain regions is a function of the design layout and the photolithographic steps required, for example, to align the various contact masks and the alignment tolerances.
[0007] Conventionally, an MOS transistor is fabricated by first forming the gate electrode and then the source and drain regions, followed by depositing a layer of interlevel oxide over the substrate. Contact holes are then patterned and cut through the interlevel oxide to expose the underlying source and drain regions. A separate mask is required to pattern the contact holes. This separate mask step further requires an alignment step whereby the mask is aligned with the edge of the gate electrode which is also the edge of the channel region. There is, of course, a predefined alignment tolerance which determines how far from the edge of the gate electrode will be the minimum location of the edge of the contact. For example, if the alignment tolerance were 1 micron, the contact wall on one side of the contact would be disposed one micron form the edge of the gate electrode and the other side of the contact would be one micron from the edge of the nearest structure on the opposite side thereof, such as another conductive contact or interconnection line. In this example, the alignment tolerance would result in a source and drain having a dimension of two microns plus the width of the contact. The overall width is therefore defined by alignment tolerances, the width of the conductive interconnection and the minimal separation from adjacent structures. A significant amount of surface area is thus dedicated primarily to mask alignment causing a substantial loss of real estate when designing densely packed integrated circuits.
[0008] When MOS devices are utilized in a complementary configuration such as CMOS devices, the additional space required to account for alignment tolerances becomes even more of a problem. This space requirement is due to the fact that CMOS devices inherently require a greater amount of substrate and surface area than functionally equivalent P-channel FET devices.
[0009] This size disadvantage is directly related to the amount of substrate surface area required for alignment and processing latitudes in the CMOS fabrication procedure to insure that the N- and P-channel transistors are suitably situated with respect to P-well formation. Additionally, it is necessary to isolate N- and P-channel transistors from each other with fixed oxide layers with an underlying channel stop region. As is well known, these channel stops are necessary to prevent the formation of parasitic channels or junction leakage between neighboring transistors. Typically, the channel stops are highly doped regions formed in the substrates surrounding each transistor and effectively block the formation of parasitic channels by substantially increasing the substrate surface inversion threshold voltage. Also, they are by necessity the opposite in conductivity type from the source and drain regions they are disposed adjacent to in order to prevent shorting. This, however, results in the formation of a highly doped, and therefore, low reverse breakdown voltage, P-N junction. Of course, by using conventional technology with the channel stops, there is a minimum distance by which adjacent transistors must by separated in order to prevent this parasitic channel from being formed and to provide adequate isolation.
[0010] It would be desirable to have a planar integrated circuit having contact openings that meet design rule criteria while minimizing distances between the contacts and nearby active areas and devices.
[0011] It is therefore an object of the present invention to provide a method of forming improved contact openings between active areas and devices for scaled semiconductor devices.
[0012] It is a further object of the present invention to provide minimum contact enclosure for the contacts to the active areas.
[0013] It is a further object of the present invention to provide a method of forming the contact openings whereby the junction leakage is minimized and the device integrity is maintained.
[0014] It is yet a further object of the present invention to provide a method of increasing the planarity of the surface of the wafer thereby minimizing subsequent step coverage problems.
[0015] Other objects and advantages of the present invention will be apparent to those of ordinary skill in the art having reference to the following specification together with the drawings.
SUMMARY OF THE INVENTION
[0016] The invention may be incorporated into a method for forming a contact opening of a semiconductor device structure, and the semiconductor device structure formed thereby. The process includes in a first embodiment, forming a first conductive structure over a portion of the integrated circuit. A thin dielectric, preferably an undoped oxide layer, is formed at least partially over the first conductive structure. A thick film is formed over the thin dielectric layer having a relatively high etch selectivity to the thin dielectric layer. The thick film is patterned and etched to form a stack over the first conductive structure. An insulation layer is formed over the thin dielectric layer and the stack wherein the stack has a relatively high etch selectivity to the insulation layer. The insulation layer is etched to expose an upper surface of the stack. The stack is then etched, isotropically or anisotropically, forming an opening in the insulation layer and exposing the thin dielectric layer in the opening. The thin dielectric layer is then etched in the opening exposing the underlying first conductive structure.
[0017] An alternative embodiment provides for a second conductive structure spaced a minimum distance away from the edge of the contact opening to meet design criteria and to insure proper electrical isolation. The second conductive structure is surrounded by a capping layer, preferably an oxide layer, to insure that the minimum distance between the edge of the second conductive structure and the edge of the contact in the opening is met. The thin dielectric layer and the capping layer will maintain the required distances between devices thus tolerating any misalignment of the contact openings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0018] The novel features believed characteristic of the invention are set forth in the appended claims. The invention itself, however, as well as a preferred mode of use, and further objects and advantages thereof, will best be understood by reference to the following detailed description of illustrative embodiments when read in conjunction with the accompanying drawings, wherein:
[0019] FIGS. 1 - 7 are cross-sectional views of the fabrication of a semiconductor integrated circuit according to one embodiment of the present invention.
[0020] FIGS. 8 - 11 are cross-sectional views of the fabrication of a semiconductor integrated circuit according to an alternative embodiment of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0021] The process steps and structures described below do not form a complete process flow for manufacturing integrated circuits. The present invention can be practiced in conjunction with integrated circuit fabrication techniques currently used in the art, and only so much of the commonly practiced process steps are included as are necessary for an understanding of the present invention. The figures representing cross-sections of portions of an integrated circuit during fabrication are not drawn to scale, but instead are drawn so as to illustrate the important features of the invention.
[0022] Referring now to FIGS. 1 - 7 , a preferred embodiment of the present invention will now be described in detail. FIG. 1 illustrates, in cross-section, a portion of an integrated circuit that has been partially fabricated. According to the example described herein, the present invention is directed to forming a contact opening which meets design criteria as such contacts are generally the most sensitive to the misalignment and design rules for spacing as described above. In addition, the present invention is further directed to increasing the planarity of the overall surface. FIG. 1 illustrates a portion of a wafer which has a surface at which isolation structures and devices in adjacent active areas are to be formed. As shown in FIG. 1, an integrated circuit is to be formed on a silicon substrate 10 . It is contemplated, of course, that the present invention will also be applicable to the formation of other contacts, including, for example, contacts between metallization and polysilicon.
[0023] The silicon substrate may be p- or n- doped silicon depending upon the location in the wafer where the isolation and active devices are to be formed. The structure of FIG. 1 includes silicon substrate 10 , into a surface of and above which is a field oxide region 12 for separating active regions or devices. Various active devices may be formed on or in the surface of the substrate as well as overlying the field oxide region 12 . In a particular application, a gate electrode 14 , formed from a first layer of polysilicon 18 , is shown overlying a gate oxide 16 . As is known in the art, typically gate electrode 14 will have sidewall oxide spacers 20 , lightly doped drain regions 22 , 24 and source and drain or diffused regions 26 , 28 . Also from the first polysilicon layer may be formed an interconnect 30 having sidewall oxide spacers 32 , 24 as is known in the art. Interconnect 30 typically will at least partially overlie field oxide region 12 .
[0024] The diffused or active region 28 is formed of opposite conductivity type from that of substrate 10 . For example, substrate 10 may be lightly doped p-type silicon and diffusion region 28 may be heavily doped n-type silicon. Of course, as noted above, other structures (with the same or opposite conductivity type selection) may alternatively be used; for example, substrate 10 may instead be a well or tub region in a CMOS process, into which diffusion or active region 28 is formed. In the example of FIG. 1, diffusion 28 is bounded by field oxide region 12 , formed in the conventional manner. In this example, diffusion 28 is relatively shallow, such as on the order of 0.15 microns, as is conventional for modern integrated circuits having sub-micron feature sizes. As such, diffusion 28 may be formed by ion implantation of the dopant followed by a high-temperature anneal to form the junction, as is well known in the art. Alternatively, the ion implantation may be performed prior to the formation of subsequent layers, with the drive-in anneal performed later in the process, if desired.
[0025] In the present invention, a thin conformal dielectric layer 38 is deposited over the wafer surface overlying diffusion 28 , field oxide region 12 and other already formed devices such as gate electrode 14 and interconnect 30 . Layer 38 may be an undoped oxide layer preferably deposited at low temperatures, for example, between 250 to 700° C. by chemical vapor deposition to a depth of about 500 to 1500 angstroms. A thick film 40 is deposited over the conformal dielectric layer 38 . Thick film 40 is preferably polysilicon or other material having a relatively high etch selectivity over the underlying conformal dielectric layer 38 . For purposes of illustration, thick film 40 will be referred to as polysilicon layer 40 and is preferably deposited to a thickness of about 10,000 to 15,000 angstroms.
[0026] Referring now to FIG. 2, polysilicon layer 40 is patterned and etched to form polysilicon stacks 42 , 44 . These polysilicon stacks are formed at locations where contacts are to be made to underlying regions such as interconnect 30 and source/drain or diffused region 28 .
[0027] Referring to FIG. 3, dielectric layer 46 is formed over the thin conformal dielectric layer 38 and over the polysilicon stacks 42 , 44 . Dielectric layer 46 is preferably borophosphorous silicate glass (BPSG) or other dielectric material which has a relatively high etch selectivity to the polysilicon stacks 42 , 44 as well as the conformal dielectric layer 38 . Dielectric layer 46 is formed for purposes of electrically isolating overlying conductive structures from all locations except where contacts are desired therebetween, for example where the polysilicon stacks are located over such regions as diffused area 28 and interconnect 30 . Dielectric layer 46 preferably has a thickness of about 10,000 to 15,000 angstroms.
[0028] Referring to FIG. 4, dielectric layer 46 is etched to expose an upper surface of the polysilicon stacks 42 , 44 . If BPSG is used as dielectric layer 46 , using a wet etch process with the etch rate of the BPSG over the polysilicon stacks of about 50:1 will allow an etch back of the dielectric layer 46 until the upper surface of the polysilicon stacks is reached or may allow for the BPSG layer to be etched below the upper surface of the polysilicon stacks to insure that the stacks are fully exposed. Other materials, etch ratios and etch chemistries may be used to achieve a similar result, for example, chemical/mechanical polishing of dielectric layer 46 may result in a relatively planar etch back exposing the upper surface of the polysilicon stacks 42 , 44 . An additional alternative may be to form a composite dielectric layer 46 by forming spin-on-glass over the BPSG and partially etching the spin-on-glass and BPSG at a 1:1 etch ratio until the upper surfaces of the polysilicon stacks are exposed. Various etch back techniques known in the art such as those described above will accomplish the desired result of partially planarizing the structure and exposing the upper surface of the stacks.
[0029] Referring to FIG. 5, the polysilicon stacks 42 , 44 are selectively etched by isotropic or anisotropic etching. The etch chemistry used will etch the polysilicon or other material used for the stacks at a high etch rate over the etch rate for the dielectric layer 46 . Contact openings 48 and 50 will thus be formed through the dielectric layer 46 where the polysilicon stacks were formed, in this example, over diffused region 28 and interconnect 30 . The thin conformed dielectric layer 38 acts as an etch stop during the polysilicon stack etch step to prevent the underlying active areas and devices from being etched away. In addition, conformal dielectric layer 38 helps to maintain the distance between the edge of the contact opening and the neighboring devices, thus maintaining required distances between devices and insuring device integrity as will be more fully described below with reference to an alternative embodiment.
[0030] The thin conformal dielectric layer 38 is next etched from the contact openings 48 , 50 exposing the active regions or devices in the contact openings. The conformal dielectric layer 38 is preferably removed by anisotropic etching to maintain the vertical dimensions or width of the contact opening. In addition to the etch back of the dielectric layer 46 , the dielectric or BPSG may be reflowed before or after etching the polysilicon stacks to increase the planarity of the dielectric layer.
[0031] Referring to FIG. 6, the polysilicon stacks were preferably patterned to have a width smaller than the width of the underlying active devices or regions, in this example, having a width of about 4000 angstroms. Thus, some misalignment of the polysilicon stacks over the active areas and devices can be tolerated. In the present example, opening 50 is shown as misaligned over diffused region 28 toward the field oxide region 12 . If this misalignment occurs over this active area, a portion of the field oxide region 12 at location 52 may be removed when the conformal dielectric layer 38 is removed from the contact opening 50 possibly reducing the area of contact between an overlying conductor and source/drain region 28 . In addition, encroaching into the field oxide may also increase potential junction leakage problems. The stack may also be misaligned over the interconnect whereby it opens over one of the sidewall oxide spacers or it may open over the interconnect line and both sidewall oxide spacers. In order to offset these problems, a thin layer of polysilicon 54 may be deposited on the dielectric layer 46 and in the openings 48 and 50 . Polysilicon layer 54 is preferably deposited to a thickness which will permit filling the openings later with a conductive material to form an interconnect to the underlying active areas or devices, for example, if the opening is approximately 4000 angstroms, polysilicon layer 50 may be deposited to a thickness of about 1000 angstroms. Polysilicon layer 54 may then be doped to help prevent junction leakage if a misalignment occurs. Polysilicon layer 54 is doped with a similar dopant as the diffused region 24 , such as by ion implantation or other suitable method. For example, if the source/drain region 28 has previously been doped with an N+ dopant such as arsenic, then polysilicon layer 54 may be doped with an N+ dopant such as phosphorous. As the polysilicon layer 54 is doped, dopants will diffuse into the substrate to some predetermined depth 56 based upon the dopant concentration and energy level. Doped region 56 will help to heal the junction region and prevent junction leakage.
[0032] Referring to FIG. 7, a conductive layer is formed over the polysilicon layer 54 , patterned and etched as known in the art to form conductive contacts 58 , 60 to the active areas and devices. Polysilicon layer 54 will typically be patterned and etched at the same time as the conductive contacts. Contacts 58 , 60 may typically be aluminum, tungsten or other suitable contact material. The present invention provides for a contact opening which tolerates misalignment or oversized contact openings and insures device integrity by healing junction exposures. In addition, the thick film and polysilicon stacks provide for a more planar structure.
[0033] Referring now to FIGS. 8 - 12 , an alternative embodiment of the present invention will now be described in detail. FIG. 8 illustrates, in cross-section, a portion of an integrated circuit that has been partially fabricated. According to the example described herein, the alternative embodiment of the present invention is also directed to forming a contact opening which meets design criteria but which is further capable of tolerating the sensitive misalignment problems and design rules for spacing as described above. FIG. 8 illustrates a portion of a wafer which has a surface at which isolation structures and devices in adjacent active areas are to be formed. As shown in FIG. 8, an integrated circuit is to be formed on a silicon substrate 70 . It is again contemplated that the alternative embodiment will also be applicable to the formation of other contacts.
[0034] As described above with reference to the preferred embodiment, the silicon substrate may be p- or n-doped silicon depending upon the location in the wafer where the isolation and active devices are to be formed. The structure of FIG. 8, includes silicon substrate 70 , into a surface of and above which is a field oxide region 72 for separating active regions or devices. Various active devices may be formed on or in the surface of the substrate as well as overlying the field oxide region 12 . In a particular application, a gate oxide layer 74 is formed over the substrate and field oxide region. A doped polysilicon or polycide layer 76 is formed over the gate oxide layer as is known in the art. An undoped dielectric layer 78 such as oxide is formed over the polysilicon layer 76 .
[0035] Referring to FIG. 9, these three layers 74 , 76 , 78 are patterned and etched to form interconnect 80 and gate electrode 88 as is known in the art. As is described above, typically gate electrode 88 will have gate oxide 90 , doped polysilicon layer 92 , sidewall oxide spacers 96 , lightly doped drain regions 97 and source and drain or diffused regions 98 . In addition, in this example, gate electrode 88 will also have a capping layer 94 formed from the undoped oxide layer 78 . Also from the first polysilicon layer may be formed interconnect 80 having a doped polysilicon layer 82 and sidewall oxide spacers 84 as is known in the art. Also, in this embodiment is shown a capping layer 86 formed from the undoped oxide layer 78 . Interconnect 80 typically will at least partially overlie field oxide region 72 . Capping layers 86 , 94 will preferably have a thickness of about 1500 to 2000 angstroms.
[0036] Similar processing steps will now be shown as described above with reference to the preferred embodiment. A thin conformal dielectric layer 100 is deposited over the wafer surface overlying diffusion region 98 , field oxide region 72 and other already formed devices such as gate electrode 88 and interconnect 80 . Conformal dielectric layer 100 is preferably an oxide layer deposited to a thickness of about 500 to 1500 angstroms. It is important, as will be discussed in detail below, that conformal dielectric layer 100 have a thickness less than the thickness of the capping layers 86 , 94 . A thick film 102 is deposited over the conformal dielectric layer 100 . Thick film 102 is again preferably polysilicon or other material having a relatively high etch selectivity over the underlying conformal dielectric layer 100 and is preferably deposited to a thickness of about 10,000 to 15,000 angstroms.
[0037] Referring now to FIG. 10, for ease of illustration of the alternative embodiment, only a contact to the source/drain or diffused region 98 will be illustrated. Contacts to other active regions or devices, is of course, contemplated. Polysilicon layer 102 is patterned and etched to form a polysilicon stack 104 . Dielectric layer 106 is formed over the thin conformal dielectric layer 100 and over the polysilicon stack 104 . As described above, dielectric layer 106 is preferably borophosphorous silicate glass (BPSG) or other dielectric material which has a relatively high etch selectivity to the polysilicon stack 104 as well as the conformal dielectric layer 100 . Dielectric layer 106 will electrically isolate the overlying conductive structures from all locations except where contacts are desired therebetween.
[0038] Referring to FIG. 11, dielectric layer 106 is etched to expose an upper surface of the polysilicon stack 104 . Various etch back techniques known in the art such as those described above will accomplish the desired result.
[0039] Referring to FIG. 12, the polysilicon stack 104 is etched by isotropic or anisotropic etching forming a contact opening 107 through the dielectric layer 106 . Polysilicon stack, in this example, is shown misaligned in the opposite direction over the source/drain region 98 and is partially aligned over the gate electrode 88 . The thin conformal dielectric layer 100 is also etched from the contact opening 107 exposing the active area 98 in the contact opening. The conformal dielectric layer 100 is preferably removed by anisotropic etching to maintain the vertical dimensions or width of the contact opening. If misalignment of the gate electrode occurs in one direction and the contact opening is misaligned in the opposite direction, a cumulative error results. This error must be accounted for by providing additional space between the edge of the gate electrode and the edge of the active area. If misalignment occurs, a portion of the capping layer 94 or sidewall oxide spacer 96 may be removed at the same time that the conformal dielectric layer 100 is etched in the opening 107 .
[0040] In this example, any misalignment of the contact opening 107 may decrease the contact space between the edge 109 of gate electrode 88 and the edge 111 of the contact opening 107 . Due to the misalignment of the contact opening, in this example, effectively opening over the sidewall spacer 96 , the distance between these active areas may be reduced enough such that the design rules for a metal contact space to gate cannot be tolerated to insure device integrity. Thus, the thickness of the capping layer 94 will insure that the required distance between the devices in order to maintain device integrity will be met. However, the thickness of the capping layer 94 must be greater than the thickness of the conformal dielectric layer 100 and thick enough that if the conformal dielectric layer 100 is overetched there will still remain enough capping layer to insure that design rules are met. In this example, the capping layer is about 1500 to 2000 angstroms while the conformal dielectric layer is about 1000 to 1500 angstroms.
[0041] As in the preferred embodiment, a polysilicon layer 108 may then be deposited to a thickness of about 1000 angstroms on the dielectric layer 106 and in the opening 107 . Polysilicon layer 106 may then be doped to help prevent junction leakage. As the polysilicon layer 108 is doped, dopants will diffuse into the substrate to some predetermined depth 110 . Doped region 110 will heal the junction region and prevent junction leakage. A conductive layer is then formed over the polysilicon layer 108 , patterned and etched along with polysilicon layer 108 as known in the art to form a conductive contact 112 to the active area 98 .
[0042] By adding the capping layer, opening the contact becomes a self-aligned feature such that the contact opening is now self-aligned to the gate. This self-aligned process can eliminate the conventional “dogbone” structure or larger enclosure needed, thereby increasing the density of devices on the integrated circuit. This process can also be used for other layers to eliminate the “dogbone” features and minimize the required design rules. As described above, in addition to the self-aligned benefit of the present invention, a more planar structure with high integrity junctions are achievable.
[0043] Although the preferred embodiment has been described in detail, it should be understood that various changes, substitutions and alterations can be made therein without departing from the spirit and scope of the invention as defined by the appended claims. | A method is provided for forming an improved contact opening of a semiconductor integrated circuit, and an integrated circuit formed according to the same. Planarization of the semiconductor structure is maximized and misalignment of contact openings is tolerated by first forming a conductive structure over a portion of a first body. A thin dielectric layer is formed at least partially over the conductive structure. A thick film, having a high etch selectivity to the thin dielectric layer, is formed over the dielectric layer. The thick film is patterned and etched to form a stack substantially over the conductive structure. An insulation layer is formed over the thin dielectric layer and the stack wherein the stack has a relatively high etch selectivity to the insulation layer. The insulation layer is etched back to expose an upper surface of the stack. The stack is then etched to form an opening in the insulation layer exposing the thin dielectric layer which acts as an etch stop during the stack etch process. The thin dielectric layer is then etched in the opening to expose the first conductive layer. A conductor is then formed in the opening contacting the underlying conductive structure. The thin dielectric under the insulation layer and on the sides of the opening near the conductive structure will increase the distance and help to electrically isolate the conductor at the edge of the contact opening from nearby active areas and devices. | 7 |
CROSS-REFERENCE TO RELATED APPLICATION
This is a continuation-in-part application of application Ser. No. 08/960,094, filed on Oct. 27, 1997, now abandoned which was a continuation of application Ser. No. 08/541,631, filed on Oct. 10, 1995, now abandoned.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The invention relates to a device and a method for the accurately metered transfer of printing ink between a fountain and a first ink roller. More particularly, the invention pertains to offset printing wherein a ductor roller is swiveled back and forth between a fountain roller and a first ink roller by a swivel mechanism that is independent of the main drive of the printing press.
2. Description of the Related Art
It has become known heretofore from German patent publication DE 39 35 215 A1 to use a ductor roller cam driven by an electromotor. The reference teaching is particularly adapted to fast-running, sheet-fed rotary printing presses, and adjusts the ductor lifting speed independently of the printing unit speed. That invention allows at high press speeds to maintain the ductor frequency below the dynamic limit of the ductor ink unit so as to satisfy the quality requirements of the color print.
The phase relationship between the movement of the printing unit and the movement of the ink ductor not being coupled is considered disadvantageous, and the inability to make a defined adjustment of the phase position of the ductor relative to the printing unit drive is also considered disadvantageous.
A further disadvantage is that the contact time of the ink ductor cannot be adjusted either at the fountain roller or at the first ink applicator roller.
According to the disclosure in German patent publication DE 23 41 510, an electromotor drives an inking unit control mechanism. Synchronization is effected by selecting a gearwheel that is driven by a main drive shaft, and an inking unit control mechanism following that gearwheel. A relative phase position of the inking unit relative to the main drive is adjustable and controlled through a pulse transducer, which senses the gearwheel position.
A disadvantage of that device is that the contact time of the ductor roller at the fountain roller and at the first inking roller is predetermined by a cam control and individual adjustments are not possible.
German Patent DE 33 24 448 C1 describes an ink metering device for letterpress and offset printing machines. The ductor roller of that device includes several mutually adjacent disks that are individually switched. The configuration leads to a problem whereby a plurality of adjusting elements and sensors are necessary for regulating and monitoring the individual disks. The resulting processing of the actuating and monitoring signals requires substantial computing capacity and a large share of available computer time. The mechanical problems resulting from the division of the ductor roller into individual disks include: severe soiling through the gaps formed in the division; a substantial amount of effort in the adjustment for the even contact of each disk at the fountain roller and at the inking roller; and exact balancing of each individual disk to avoid oscillations.
SUMMARY OF THE INVENTION
It is accordingly an object of the invention to provide a device and a method for the controlled transfer of printing ink, which overcomes the above-mentioned disadvantages of the heretofore-known devices and methods of this general type and which provides a novel inking process and an associated ink ductor device that is driven independently of the drive of the printing machine (printing unit) and that is individually adjustable.
With the foregoing and other objects in view there is provided, in accordance with the invention, an assembly for the exactly metered transfer of printing ink in a printing unit, comprising:
a fountain roller receiving ink from an ink fountain, and a first ink roller of the printing unit spaced apart from the fountain roller;
a ductor roller and a swivel mechanism for swiveling the ductor roller back and forth between the fountain roller and the first ink roller; and
the swivel mechanism including a swivel drive being operable independently of a main drive of the printing unit, and being a discontinuous drive. The discontinuous drive is preferably a linear drive, such as a linear motor or a piezo actuator.
As set forth above, the ink ductor roller alternately contacts the fountain roller and the first ink distribution roller. Accordingly, an ink ductor cycle is defined as the number of times the ink ductor roller contacts the first ink distribution roller per revolution of the plate cylinder. One such back-and-forth motion of the ductor roller is defined as one ductor beat
With the above and other objects in view there is also provided, in accordance with the invention, a method of transferring printing ink from a fountain roller to a first ink roller in a printing unit, wherein a ductor roller is swiveled back and forth between an ink fountain and a first ink roller by a swivel mechanism, which is driven independently of a main drive of the printing machine, which includes the steps of:
individually adjusting each of the following parameters:
a phase relationship between the ductor roller and a plate cylinder of the printing unit;
a number of ductor beats per machine revolution (revolution of the cylinders of a printing unit); and
a contact time of the ductor roller at the fountain roller and a contact time of the ductor roller at the first ink roller.
In accordance with another mode of the invention, the method further comprises adjusting the number of ductor beats per machine revolution, and the contact time of the ductor roller at the fountain roller and at the first ink roller differently during a printing operation as compared to a non-printing operation.
In accordance with another mode of the invention, one or more ductor beats are omitted after one or several ductor beats.
In accordance with a concomitant feature of the invention, the method comprises driving the swivel mechanism such that, upon print shut-down, the ductor roller is in contact with the ink distribution roller.
The advantage of the invention is found in the simplicity of the construction and in the multiplicity of variation possibilities given by the independence of the ink ductor.
The structural simplification is found in the fact that no complicated transmission, linkages, etc., are necessary for deriving the motion from the gear train. The synchronization relative to the main drive is effected through an incremental transducer that is present in any case and that is read into a computer system and evaluated therein.
The novel computer-regulated system realizes several advantages.
First, the phase position of the ductor, i.e., the point in time in which the ductor contacts the first inking roller, can be adjusted such that possibly incurred oscillations have the least impact on the print quality. The adjustment could be, for instance, the time when the ink applicator rollers face the groove in the plate cylinder. Another possibility could be to select a position on the printed image that is least critical.
Second, the direct and discontinuous drive of the ductor swivel assembly leads to the advantage that the contact speed at exactly the moment when the ductor roller contacts the fountain roller or the first ink roller may be chosen such that virtually no vibrations are induced.
The adjustable contact time at the fountain roller and at the first ink roller offers the printing press operator the advantage that he or she may freely choose the ductor rhythm, i.e., the number of ductor swivel movements per machine rotation (revolution of the cylinders of a printing unit), independently of the subject image to be printed. At small lifting speed, it is possible to transport correspondingly more ink from the fountain roller to the first ink roller, which makes it further possible to influence the amount of ink additionally with the thickness of the ink layers, and, thus, to adjust the same with zonal variations. Reduced lifting speeds are only chosen when a subject is to be printed with relatively little inking. As a rule, 1/2 or 1/3 speed adjustment is chosen. It is thereby also possible to adjust a different lifting speed or rhythm in each printing unit.
With a ductor motion that is operated independently of the machine phase (the phase of the plate cylinder of the printing unit), it is a further possibility for the ductor speed to be adjusted unevenly, i.e., one or more ductor movements may be omitted after a certain number of ductor movements.
A further advantage of the novel control is that, when the printing operation of the printing unit is stopped, the drive is stopped such that the ductor roller happens to contact the ink oscillator roller at stillstand.
Other features that are considered as characteristic for the invention are set forth in the appended claims.
Although the invention is illustrated and described herein as embodied in a device and method for the controlled transfer of printing ink, it is nevertheless not intended to be limited to the details shown, because various modifications and structural changes may be made therein without departing from the spirit of the invention and within the scope and range of equivalents of the claims.
The construction of the invention, however, together with additional objects and advantages thereof will be best understood from the following description of the specific embodiment when read in connection with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic view of an assembly for swivelling a ductor roller between a fountain roller and an ink distribution roller according to the invention;
FIG. 2 is a diagrammatic view of a system for regulating the ink strip width, the ink ductor speed and the phase position according to the invention;
FIG. 2a is a more detailed block diagram of FIG. 2 showing additional control functions.
FIG. 2b is a flow chart showing the major function steps of the claimed method.
FIG. 3 is a similar view of an embodiment with a stepper motor;
FIGS. 4 and 5 are schematic views of ductor roller swivel systems; and
FIG. 6 is a diagrammatic view of the course of the speed U of the ink ductor roller relative to a time line.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
In all the figures of the drawing, sub-features and integral parts that correspond to one another bear the same reference symbol in each case.
Referring now to the figures of the drawing in detail and first, particularly, to FIG. 1 thereof, there is seen a ductor roller or vibrator 1, which is mounted in an angled lever 2. The angled lever 2 is articulated about a pivot point 3 and is moved up and down by a cam drive 4 through a cam roller 5. The articulation causes the ductor roller 1 to swivel back and forth between a fountain roller 6 and an ink distribution roller 7. One such back-and-forth motion of the ductor roller 1 is defined herein as one ductor beat.
In alternative terminology, the fountain roller 6 may be referred to as the ductor, the roller 1 may be referred to as the vibrator and the roller 7 may be referred to as the oscillator.
When the ductor roller 1 is in contact with the fountain roller 6, the ductor roller 1 receives ink that was taken by the fountain roller 6 from a fountain or ink supply box 8. After swivelling, the ductor roller 1 transfers the ink to the ink distribution roller 7. The fountain roller 6 and the ink distribution roller 7 are driven through a non-illustrated gear train or by a non-illustrated motor. The ink ductor roller 1 does not have a drive. Rather, the ductor roller 1 is rotatably driven by friction with the fountain roller 6 on the one hand and with the ink roller 7 on the other hand. A spring 9 ensures that the roller 5 always rolls on the cam drive 4.
FIG. 2 illustrates a setpoint generator 11 that receives the following values input by an operator:
Sb=the strip width, i.e., the amount of ink to be transferred from the fountain roller 6 to the ink ductor roller 1;
Kt=the ink ductor speed, i.e., the number of ductor beats per machine revolution;
φ DW-H =the phase relationship between the ink ductor and the plate cylinder of the printing unit.
The setpoint generator 11 receives the actual angular speed φ DW of the plate cylinder of the printing unit and the angular position η DW of the plate cylinder of the printing unit from an incremental angular sensor 12. From these input values the setpoint generator 11 produces a setpoint angle φ s and an angular speed setpoint η s . These setpoint values (φ s , η s ) are supplied to an angular phase adjustment device 14 and to an angular speed regulator 15. The angular speed regulator 15 produces a setpoint current i s , which is fed to a power member 16. The power member 16 controls the motor 17, at whose shaft 18 the cam drive 4 is mechanically secured. The motor is preferably a linear drive, such as a linear motor or a piezo actuator. Another incremental angle sensor 19 is disposed on the shaft 18 and determines the actual values of the angular speed η H and the angular position φ H of cam shaft 18. These values are fed back to adder stages 13a and 13b with a negative sign.
FIG. 3 shows a setpoint generator 11 that, as in FIG. 2, produces a signal from the input signals Sb, Kt, φ DW-H , φ DW , and η DW . The signal is fed to a stepper control 21. The stepper control 21 regulates a power member 16, which forms the current supply for the stepping motor 22. The stepper motor 22 moves the ductor roller 1 through a shaft 18 between the fountain roller 6 and the ink distribution roller 7. This embodiment provides the advantage of eliminating feedback with regard to the position of the stepping motor 22.
FIG. 4 shows a motor 31--the construction of which is not specified herein--that is connected to a cam disk segment 32. The cam disk segment 32 has different radii r 1 and r 2 . A roller 5 runs on the cam disk segment 32 and the roller 5 is operatively connected with the angled lever 2. The angled lever 2 is articulated about the pivot point 3 and, upon rotation of the motor 31, the angled lever 2 pivots the ductor roller 1 back and forth between the fountain roller 6 and the ink distribution roller 7.
FIG. 5 shows a similar system for swiveling the ductor roller 1 as in FIG. 4, however with a linear motor 41 that directly engages the angled lever 2. The deflection of the linear motor 41 effects a back-and-forth oscillation of the ductor roller 1 through the angled lever 2. The linear motor 41 can also be a piezo actuator 41.
FIG. 6 illustrates an idealized course of the peripheral speed U of the ductor roller 1. At time t 0 , the ductor roller 1 lies in contact with the ink distribution roller 7. Thus, the ink distribution roller 7 drives the ductor roller 1 during the period of time from t 0 to t 1 , i.e., the ink is transferred from the ductor roller 1 to the ink distribution roller 7. At time t 1 the ductor roller 1 is separated from the ink distribution roller 7 and swiveled to the fountain roller 6, and the ductor roller 1 contacts the fountain roller 6 at time t 2 . The speed of the ductor roller 1 is not defined during the period of time between t 1 and t 2 . The peripheral speed of the ductor roller 1 is equal to that of the fountain roller 6 during the period of time from t 2 to t 3 . The ink is thereby transferred from the fountain roller 6 to the ductor roller 1. At time t 3 , the ductor roller 1 is separated from the fountain roller 6 and is swiveled back to the ink distribution roller 7. In the period of time from t 3 to t 0 , the speed of the ductor roller is again undefined.
The period of time from t 0 to t 1 and from t 2 to t 3 , as well as the phase position at the times t 0 and t 2 relative to the movement of the plate cylinder of the printing unit can be individually adjusted by the printing press operator with regard to the specific print job or the properties in the printing unit. A maximum of the time period from t 2 to t 3 is suitably chosen such that the ductor roller 1 contacts the fountain roller 6 during one revolution.
FIG. 2a shows more details of the control than FIG. 2, including the setpoint generator 11, the respective angular phase adjustment device 14, and the angular speed generator 15.
Input to the setpoint generator 11 are the values Sb for the ink strip width, the ink ductor speed Kt, i.e., the number of ductor beats per machine revolution, and the phase angle φ DW-H between the ductor roller 1 activation and the plate cylinder of the printing unit. This phase angle may, as an example, be entered by the machine operator. The setpoint generator 11 receives additional information relating to the speed of the plate cylinder of the printing unit (η DW ) and its angular position, i.e., phase angle φ DW . These values are provided from the incremental angular sensor 12. In order to provide the angular position, i.e., the phase angle φ DW , an additional computational step is required (2π/S). The setpoint generator 11 provides from the received inputs (Sb, Kt, φ DW-H , η DW , and φ DW ) , the nominal, i.e., setpoint, values for the phase setpoint device 14 and angular speed regulator 15. The phase setpoint device 14 is constructed as a proportional controller, having a gain factor K p . The angular speed regulator 15 is constructed as a proportional-integral controller having an amplification factor Kpi(1+Tpi s )/S.
The power member 16, the motor 17, and the cam drive 4 in combination provide the control function, which is expressed mathematically by the function K s /(1+T s S). The control function performed by the control elements 16, 17, 4 are connected to the incremental angle sensor 19, which provides the rotational speed η H of the motor 17. The rotational speed value η H is coupled through summing circuit 13b as an actual value to the angular speed regulator 15, and a computation step 2π/S provides the angle value φ H from the rotational speed value η H . The angle value φ H is entered into the angular phase adjustment device 14 as an actual angle value φ H .
After starting the press, the settings are entered, which the printing press operator enters before start of a printing job. These settings are the width Sb of the ink strip applied to the printing material, the ink ductor repetition rate Kt, and the active phase angle of the ductor swivel assembly relative to the plate cylinder. In the next step, the actual printing parameters for the printing unit are entered. The latter are the actual angle position of the printing unit, such as plate cylinder phase angle φ DW and the actual rotational speed η DW of the plate cylinder of the printing unit.
In a next step, a computation is performed, wherein the setpoint values φ sol1 and η sol1 for the ductor swivel assembly are computed. The setpoint values are next transmitted to the angular phase adjustment device 14 and to the angular speed controller 15. In a last program step, it is determined if the press has stopped. If this is not the case, the process is repeated from the beginning.
The device described herein is particularly suitable for offset and letterpress printing and it is applicable for all undershot fountain inking units.
FIG. 2b is a flow chart showing the major steps of the disclosed method. After start (100), the printing strip width Sb, the repetition rate Kt, and the phase angle φ DW-H of the plate cylinder of printing unit are entered in step 101. In step 102 the printing parameters φ DW , representing the angular position of the plate cylinder of the printing unit, and the rotational speed η DW of the plate cylinder of the printing unit are entered. In step 103, the setpoint values, namely the phase setpoint value φS and the angular speed η s . | Ink is accurately metered in the defined transfer thereof from a fountain roller to a first ink roller in a printing unit. A ductor roller is swiveled back and forth between the ink fountain and the ink roller with a swivel mechanism. The swivel mechanism is driven independently of a main drive of the printing unit and with a discontinuous drive. Several parameters are thereby individually adjusted, among them a phase relationship between the ductor roller and a plate cylinder of the printing unit, a number of ductor beats per revolution of the cylinders of the printing unit, and a contact time of the ductor roller at the fountain roller and a contact time of the ductor roller at the first ink roller. | 1 |
BACKGROUND OF THE INVENTION
The present invention pertains to cutting metal workpieces with a cutting torch and, more particularly, to an apparatus and method for handling torch cut edge trim pieces by cutting them to manageable lengths without interfering with the continuous operation of the main edge cutting torch.
In the production of continuously cast steel slabs, it is customary to trim one or both lateral edges of the slab to obtain a desired slab width. Edge trimming is typically accomplished by moving a carriage-mounted cutting torch longitudinally over the slab along a linear path defining the edge cut. Slabs may typically range in thickness from three to twelve inches (about 75 to 300 mm) and, as a result, the edge-cut trim piece or pieces eventually become so long that they are unwieldy and difficult to handle. Therefore, as a trim piece is continuously cut from a slab, it is customary to periodically cut the trim piece into manageable lengths so they can be easily handled and disposed of. If the movement of the main edge cutting torch is interrupted to make a trim cut, production time may be lost and the quality of the cut edge of the slab may be adversely affected.
A similar problem occurs in conventional shape cutting machines in which a plate is traversed by an overhead cutting torch which, in certain cases, leaves a long scrap edge piece. Typically, the machine operator will periodically cut the scrap edge piece into short manageable lengths with a hand-held cutting torch.
The prior art describes processes and apparatus for making a transverse cut across a metal billet or slab. For example, U.S. Pat. No. 5,102,473 shows adjustable angular sliding movement of a cutting torch over a moving billet to make a transverse right angle cut. U.S. Pat. Nos. 2,202,130 and 4,179,101 show multi-torch head machines for cutting and edge shaping. U.S. Pat. No. 4,281,822 discloses the use of separate longitudinal and cross cut torches, each of which is carriage-mounted and operated in a conventional manner to provide respective longitudinal and transverse cuts in a moving slab from a continuous casting machine.
SUMMARY OF THE INVENTION
In accordance with the present invention, edge-cut scrap pieces are cut to manageable lengths automatically and without interrupting the main edge trimming process with an independent cross cutting torch that moves with the main edge cutting torch and is additionally driven to move at a selected angle and/or speed periodically across the edge-cut scrap piece to provide a manageable length piece.
The apparatus of the present invention includes a carriage which is mounted horizontally over and is movable relative to the slab or other workpiece in the direction of the desired edge-cut and at a selected edge cutting speed. An edge cutting torch is mounted on the carriage for movement therewith along the path of the edge trim cut. A crosscutting torch is also mounted on the carriage for movement therewith and for independent horizontal movement across the edge-cut piece at an acute angle to the path of the edge cut and at a selected crosscutting speed. Means are also provided for adjusting one or both of the angle of movement and the speed of the cross cutting torch to provide a cross cut which is generally transverse to the cut edge.
Preferably, the cross cutting torch is mounted on a cross cut track which is pivotally attached to the carriage for horizontal angular adjustment on a vertical axis. The cross cutting torch is mounted to trail the edge cutting torch in the direction of the edge cut path and a crosscut torch drive moves the crosscut torch along the track from the cut edge to the outer edge of the edge-cut piece.
Drive means provides relative movement between the carriage and the workpiece and movement of the crosscut torch on the carriage. Preferably, the carriage drive is operative to move the carriage along the workpiece.
In accordance with the corresponding method of the present invention, a metal workpiece is simultaneously edge-cut to form a trim piece and the edge-cut trim piece is cut into manageable lengths utilizing the steps of (1) mounting a carriage to operate horizontally relative to the metal workpiece in the direction of the desired edge-cut and at a selected edge cutting speed, (2) mounting an edge cutting torch on the carriage for movement therewith along a path of the cut edge, (3) mounting a crosscutting torch on the carriage for movement therewith and for independent horizontal movement across the edge-cut piece at an acute angle to the path of the edge cut and at a selected crosscutting speed, and (4) adjusting at least one of the angle of movement and the crosscutting speed to provide a crosscut generally transverse to the edge-cut.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is an end elevation view of a carriage for the two cutting torches of the present invention which are shown positioned to make the edge-cut and crosscut on a metal slab.
FIG. 2 is an enlarged sectional detail taken on line 2--2 of FIG. 1.
FIG. 3A is a further enlarged detail of FIG. 2 showing the crosscutting torch prior to commencement of the crosscut.
FIG. 3B is a further enlarged detail circumscribed by line 3B--3B of FIG. 2 showing the crosscutting torch as positioned therein.
FIG. 3C is a further enlarged detail similar to FIGS. 3A and 3B showing the crosscutting torch at the completion of its cut.
FIG. 4 is a vector diagram showing the relative speeds of the edge cutting and crosscutting torches required to provide the desired transverse crosscut.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring to FIG. 1, a metal slab 10, such as formed for example from continuous cast steel, is shown in transverse cross section carried on a conventional support 11. A slab cutting machine 12 is of a conventional cantilever construction, but other torch-carrying cutting machines may also be utilized with the apparatus of the present invention and in a manner utilizing the method of this invention. The cutting machine 12 includes a wheeled truck 13 adapted to move along a pair of tracks 14 which extend longitudinally along one side of the slab 10. Extending in cantilever fashion from one side of the truck 13 is a carriage arm 15 which is positioned to extend over the slab 10. A guide wheel carriage 16 is mounted on the inner end of the carriage arm 15 and includes one or more guide wheels 17 adapted to engage and ride along one edge of the slab 10 as the truck 13 moves along the tracks 14. The position of the guide wheel carriage 16 can be selectively varied with a lateral positioning device such as a fluid cylinder 18.
A torch carriage 20 is mounted on the outer end of the carriage arm 15 for positioning movement along the arm. The torch carriage 20 may be moved and positioned along the carriage arm by a separate positioning motor 21 or a similar device. Depending downwardly from the torch carriage 20 are a main edge cutting torch 22 and a secondary crosscutting torch 23. A second torch carriage (not shown) may be added in place of the guide wheel carriage 16. In this case, extensible guide wheels or guide rollers are carried by the truck 13 and take the place of the guide wheels 17.
Referring also to FIG. 2, to provide a conventional edge trim cut 24, the torch carriage 20 is moved laterally along the carriage arm 15 to a selected edge position above the slab 10. The carriage truck 13 is then driven along the side of the slab and the edge cutting torch 22 is operated to provide the indicated trim cut. The cutting torches 22 and 23 may be conventional oxy-fuel torches, but may alternately comprise plasma torches or any other type of non-contact cutting tool. The apparatus described to this point and its operation are conventional.
As the cutting machine 12 moves along the length of a long slab, the trim cut 24 forms an edge-cut scrap piece 25 which must be periodically cut to manageable lengths for handling and disposal. A transverse cross cut 26 to create the short manageable scrap piece is provided by the crosscutting torch 23. Referring also to FIGS. 3A--3C, the crosscutting torch 23 is mounted to travel horizontally along a crosscut track 27. The crosscut track, in turn, is connected to the torch carriage 20 on a vertical pivot 28, so that the horizontal angular orientation of the crosscut track 27 may be selectively varied. The crosscutting torch 23 depends downwardly from a torch mounting bracket 31 which, in turn, is carried by a slide mechanism 30 operable along the crosscut track 27. The slide mechanism 30 may be operated by any conventional actuator, such as a rack and pinion, fluid operated actuator, and the like. Preferably, the slide mechanism operator may be adjusted to operate at selected speeds and, in combination with the angular adjustability of the crosscut track 27 on its pivot 28, the cross cutting torch 23 may be set to provide a true transverse crosscut 26 simultaneously with continuous operation of the edge cutting torch 28 creating the main trim cut 24, all in a manner which will be described hereinafter.
In FIG. 4, the vector V a represents the velocity of edge cutting torch 22 which, of course, is the velocity of the cutting machine truck 13 moving along the lateral edge of the slab 10. The vector V b represents the desired effective crosscutting velocity of the crosscutting torch 23 to provide a crosscut 26 that is transverse to the main trim cut 24. The vector V c represents the actual velocity of the crosscutting torch 23 as it moves along the crosscut track 27 at an acute angle θ with respect to the linear path of the trim cut 24. The pivotal mounting 28 of the crosscut torch track 27 is positioned in alignment with the edge cutting torch 22 on the linear path of the trim cut 24 and to trail the edge cutting torch along its path of trim cutting movement. With the proper selection of crosscut track angle and crosscutting torch speed, the angular movement of the crosscutting torch along its track 27, while it is simultaneously carried on the torch carriage 20 in the direction of the trim cut 24, will produce the transverse crosscut 26 at the desired crosscutting velocity V b . For example to provide a trim cut 24 of desired high quality in a slab of given thickness, it may be desirable to operate the edge cutting torch 22 at a cutting velocity V a of ten inches per minute (about 250 mm per minute). Because the quality of the crosscut 26 forming a manageable length scrap piece does not have to be particularly good, it may be desirable to provide an effective crosscut velocity V b somewhat slower than the edge cutting torch velocity V a in order to assure that the crosscut starts properly, continues across the full width of the edge-cut piece, and is not lost during the crosscutting operation. A crosscut velocity V b of, for example, eight inches per minute (about 200 mm per minute) might be chosen. Using conventional trigonometric calculation, the angle θ, defining the acute angle between the trim cut 24 and the cross cut track 27 is 38.66°, and the actual velocity V c of the crosscutting torch 23 along the track 27 is 12.8 inches per minute (about 320 mm per minute). The angle θ may be adjusted in either direction with a corresponding adjustment in the crosscutting torch speed V c while still maintaining a generally transverse direction to the crosscut 26.
It is important to prevent the crosscutting torch 23 from moving laterally inwardly over the slab beyond the trim cut 24 in order to avoid undesired damage to the trim cut edge of the slab. Appropriate stops on the crosscut track 27 may be provided to prevent movement of the crosscut torch 23 inwardly beyond the approximate position of the vertical pivot 28. The wide variability in angular adjustment of the crosscut track 27 and in the selected actual crosscutting torch velocity V c permits the system to be adapted to address other considerations. For example, if the crosscut trim pieces have value beyond mere scrap value, the crosscut velocity V b may be selected to be close to or the same as the edge cutting torch velocity V a to provide a better and more precise crosscut 26.
The apparatus and method of its operation of the present invention may also be applied to a conventional shape cutting machine in which programmed operation of a main cutting torch over a workpiece comprising a horizontal plate produces desired torch-cut shapes. Such shape cutting operations typically also result in edge trim pieces which must be periodically cut to manageable lengths and removed from the cutting table. An auxiliary crosscutting torch of the type described above may be mounted on the main torch cutting head and operated in the manner described above to periodically cut the edge trim piece laterally into manageable lengths. | An edge trimmed piece that is cut from a long metal slab with a cutting torch carried along the slab edge is automatically crosscut into short manageable length pieces with a secondary crosscutting torch. Both torches are mounted on the same carriage and the crosscutting torch is periodically activated to move along an acute angular path with respect to the edge trim cut, resulting in an effective crosscut transverse to the main trim cut. The crosscutting operation may be carried out without interruption of the edge trim torch, thereby enhancing productivity and trim cut quality. | 1 |
BACKGROUND OF THE INVENTION
This invention relates generally to nuclear reactor fuel assemblies and more particularly to providing a wear sleeve in the control rod guide tubes of the assembly whereby vibration of the control rod will not damage the guide tube.
Nuclear reactors of the pressurized water type typically have a core region consisting of a multiplicity of vertically oriented fuel assemblies, each assembly containing a matrix of fuel pins. The assembly skeleton includes a plurality of elongated guide tubes to which are connected grids for supporting the fuel pins, and end fittings for securing the assembly between vertically spaced support plates. The guide tubes also serve as sheaths for control rods which are inserted into the core for the purpose of controlling the heat output of the fuel. An upward flow of liquid is maintained in the guide tube to cool the control rod.
Examination of selected fuel assemblies during the refueling of some reactors of this type has revealed the existence of wear patterns on the inside of the guide tubes at the elevation corresponding to the position of the control rod tip within the guide tube when the rod is in the upper limit of travel, i.e., the unique "withdrawn" position. Such wear behavior has the potential for perforating the guide tubes and weakening them so much that the integrity of the assembly might be in doubt. Significant weakening of the guide tubes is particularly dangerous during refueling when the full weight of the assembly is borne by the guide tubes. Thus, further wear of guide tubes in assemblies that are present in a particular reactor must be prevented, and new assemblies that have been fabricated but not yet loaded into the reactor should be modified to avoid such wear.
Modifying fuel assemblies after they have been in the reactor, or when stored on site prior to placement in the reactor, is a difficult task because the assemblies are typically kept under water. Thus, the modification must be made remotely. Accordingly, the problem addressed by the present invention preferably is solved in a way that is easily adopted for remote modification of worn guide tubes.
SUMMARY OF THE INVENTION
The present invention provides a wear sleeve for a guide tube in a nuclear fuel assembly, and a method of installing the sleeve. The sleeve is an elongated metal cylinder having an upper portion adapted to be suspended from the upper end of the guide tube, and a lower portion adapted to be permanently deformed into interference fit with the walls of the guide tube whereby the sleeve may be secured against vertical movement.
The method of installing the sleeve includes the steps of suspending the sleeve from the upper end of the guide tube, then expanding a selected lower surface of the sleeve until the sleeve is permanently deformed, whereby an interference fit between the sleeve and tube is formed.
After the sleeve is installed in the guide tube, the tube must perform substantially like an unrepaired tube, except of course, it has better resistance to control rod vibration. Accordingly, it is an object of the present invention to provide a sleeved guide tube which does not inhibit the insertion and withdrawal of the control rod within the tube. In addition, the control rod must be sufficiently cooled, and the possibility of corrosion between the sleeve and tube minimized. Furthermore, the sleeve should be compatible with fuel assemblies that are reconstitutable.
BRIEF DESCRIPTION OF THE DRAWINGS
The present invention satisfies these and other objectives, as will be evident from the following description and accompanying drawings in which:
FIG. 1 is an elevation view, partly in section, showing the wear sleeve secured to the guide tube;
FIG. 2 is an elevation view, partly cut away, showing the wear sleeve before insertion into the guide tube;
FIG. 3 is a schematic view in section, showing in exaggerated detail the shape of the sleeve as secured to the tube;
FIG. 4 is a view along the lines 4--4 of FIG. 2;
FIG. 5 is a view along the lines 5--5 of FIG. 2;
FIG. 6 is a section view of the elastomer expansion plug for forming the crimp connection between the sleeve and the guide tube; and
FIG. 7 is a section view of one embodiment of a tool with which an elastomer expansion plug may be mounted prior to insertion into the sleeve.
DESCRIPTION OF THE PREFERRED EMBODIMENT
FIG. 1 shows a fuel assembly 10 having a plurality of guide tubes 12 (one shown), the guide tube 12 including a post 14 threadedly connected at 16 to an enlarged portion 18 of the tube. An end plate 20 is disposed between the post 14 and the cylindrical portion of the guide tube 12. The assembly 10 further includes grids 22 connected to the guide tube 12 for supporting the fuel pins 24. The fuel pins 24 typically extend parallel to the guide tube 12 and terminate just below the end plate 20. The active, heat-producing material in the fuel rods 24 typically terminates approximately 6 to 10 inches below the top of the fuel 24. The top of the active fuel is designated by arrow 25 in FIG. 1.
The guide tube 12 serves as a sheath for the control rod 26 which telescopingly reciprocates therein. The control rod 26 has a unique upper limit position, typically called the fully "withdrawn" position, whereby the control rod tip 28 is at or above the top of the active fuel 25. In this embodiment of the invention, the withdrawn position is at the same elevation 25 as the top of the active fuel. The control rod 26 may be up to 14 feet long, and is suspended at its upper end from a drive mechanism (not shown) which controls the vertical movement thereof. As a result of the cantilevered support of the control rod 26, and the upward coolant flow through the guide tube 12, the control rod 26 when withdrawn seems to oscillate against the inner wall of the guide tube 12, producing a wear pattern over a critical region 30 of the guide tube 12. The guide tube 12 is particularly vulnerable to contact with the control rod 26 because the typical guide tube material is Zircaloy, which is softer than the Inconel control rod clad.
The present invention provides a method of installing a sacrificial wear sleeve 32 into the upper portion of the guide tube 12 to accommodate the oscillation of the control rod tip 28 and prevent further wear on the guide tube walls. The sleeve 32 is suspended from the post 14 at the upper end of the guide tube 12 and secured to the guide tube 12 by a crimp 34 in which the sleeve 32 and guide tube 12 are permanently deformed. The sleeve 32 remains in place for the lifetime of the assembly 10 but can be replaced in the event the assembly 10 is reconstituted, as described below.
In a typical pressurized water reactor the distance from the top of the post 14 to the critical region 30 is between 15 and 24 inches; in the illustrated embodiment this distance is about 22 inches. The guide tube inner and outer diameters are 0.900 and 0.980 inches, respectively, and the control rod outer diameter is 0.816 inches. The length of the sleeve 32 is 27 inches, the lower 10 inches of which are expanded into intimate contact with the guide tube walls, as is best shown in FIG. 3. This embodiment represents a fuel assembly which has been fabricated and may or may not have been present in the reactor, but has not yet experienced any guide tube wear. Thus, the expanded region 36 may extend above the critical region 30 without danger of perforating the guide tube walls. In assemblies 10 that have significant guide tube wear, the sleeve is expanded from the lower end to a point below the critical region 30.
The expansion of the sleeve over region 36 is intended to maximize the flow area between the control rod 26 and the sleeve 32 in the vicinity of the active fuel 24, and improve radial heat flow from the inner diameter of the sleeve 32 to the outer diameter of guide tube 12, particularly when the rod 26 is residing in the active fuel. If the flow area is too small, boiling of the coolant may occur resulting in possible corrosion product build up. It should be understood that, even when the control rod tip 28 is in the withdrawn position, heat is generated therein as a result of neutron absorption in the B-10 atoms of the control rod. The spatial variations of the intensity of the neutron flux above the active fuel may vary with the particular reactor and accordingly, the axial extent of the expanded portion 36 of the sleeve 32 is determined by the axial extent of the need for protection against coolant boiling. As indicated above, it is not recommended that the expansion of the sleeve be made in the critical region 30 if the tube has been weakened due to control rod vibration, depsite the loss of protection against local boiling.
FIG. 2 shows the sleeve 32 in detail before insertion into the guide tube 12. The entire inner surface is preferably chrome-plated to a thickness of at least 0.001 inch, especially in the portion of the lower end to be located in the critical region 30. The thickness of the sleeve 32 is about 0.014 inches over the entire length. Except for the upper and lower ends 38, 40 respectively, the inner diameter is 0.863 inches (before plating) and the outer diameter is about 0.890 inches. In order to assure unrestricted vertical movement of the control rod 26 within the sleeve 32, the sleeve should permit a 28 inch long plug having a uniform outer diameter of at least 0.850 inches to pass through unobstructed.
The upper end 38 of the sleeve is conical and adapted to hang from the flared upper end 42 of the post (FIG. 3), which in this embodiment is angled about 4 to 5 degrees from the vertical. Other shapes in which a generally flanged end 38 may be suspended from a stop surface in the upper end 42 of the guide tube 12 or post 14 are also acceptable, so long as the interaction therebetween provides positive support and unique vertical positioning of the sleeve 32 with respect to the tube 12. The present invention does not require that the flare 44 and flange 38 surfaces be attached or mechanically joined. Preferably, the outside surface of the flange 38 is also chrome-plated to resist any wear arising from possible vibration of the flange 38 against the flare 44. This may arise because the flange 38 is not fixedly attached to the stop surface 44 of the tube 12. The intermediate portion of the sleeve 32 has a plurality of coolant flow openings including holes 46 and slots 48, the purpose of which will be explained below. The lower end 40 of the sleeve is tapered in order to reduce the possibility of scratching the control rod 26 as it moves along the discontinuity between the sleeve 32 and the tube 12.
The method of installing the sleeve 32 into the guide tube 12 will be described with reference to FIGS. 1 and 3. It is to be understood that, depending on the history of the particular fuel assembly to be modified, the sleeve installation will be performed from a variety of remote positions. The following description is generic to all installation methods in which there is no direct human contact with the guide tube 12.
First, the sleeve 32 is placed into the upper end 42 of the post 14 so that the flange 38 is suspended from the flared portion 44 of the post. This step locates the tapered end 40 of the sleeve 32 about 5 inches below the critical region 30. The next step is to expand the lower portion 36 of the sleeve 32 into intimate contact with the tube 12. In this embodiment the tube 12 is made of Zircaloy, which has a lower coefficient of expansion than the stainless steel sleeve 32. Since the sleeving operation will be performed at room temperature, the sleeve 32 alone can be expanded so that the maximum diametral gap between the sleeve portion 36 and guide tube 12 is about 0.0025 inches. At operating temperatures (averaging about 590° F), the sleeve 32 will expand more than the tube 12, thereby effecting the intimate contact. The conical upper end 38 of the sleeve will freely rise relative to the post 14, but will not protrude beyond the end 42, since room for expansion has been provided. Although the tube may be permitted to expand slightly as the sleeve is expanded over portion 36, the percent diametral increase in tube strain should not exceed about 0.005.
After the sleeve 32 has been suspended from the flared portion 44 of the post 14, and the sleeve 32 has been expanded over the region 36, the final step in the installation is to mechanically secure the sleeve 32 to the tube 12 below the critical region 30. In the preferred embodiment, the sleeve 32 and guide tube 12 are crimped into a permanent deformation 34 which provides an interference fit therebetween. The crimp 34 is sufficient to provide a large enough resistance to secure the sleeve 32 within the tube 12 during normal reactor operation so that there is no danger of the sleeve 32 loosening as a result of the coolant flow through the tube 12, or of continued control rod vibration. The crimp 34 is not so tight, however, to preclude pulling the sleeve 32 out of the tube 12 in the event the assembly must be reconstituted during a subsequent refueling. The sleeve 32 can be withdrawn from the tube 12 by application of a lift force of about 1500±500 pounds applied on the inner surface of the sleeve 32. Once the sleeve 32 is removed, the post 14 can be unscrewed from the guide tube 12 at connection 16, the end plate 20 removed, and the fuel pins 24 replaced as needed. After reconstituting the assembly, a new sleeve 32 can be installed by the method described herein.
The crimp 34 should be made as low as practicable on the sleeve 32 to avoid the possibility of flutter as the coolant contacts the lower edge 40 of the sleeve 32. Although the crimp 34 could be centered on the bottom edge 48 of the tapered end 40, it has been found that, with the elastomer expansion plug to be described below, it is preferable to make the crimp 34 about one inch above the edge 48. In the preferred embodiment, the permanent deformation of the tube outer diameter at the peak of the crimp 34 is about 0.015 to 0.035 inches relative to the nominal tube outer diameter on either side of the crimp.
One technique for expanding the sleeve 32 against the tube 12 over portion 36 and for forming the crimp 34 includes hydroswaging with an elastomer expansion plug of the type shown in FIGS. 6 and 7. The expansion plugs are shown in phantom in FIG. 3. A generally cylindrical tool 50 carrying the expansion plug 52 is inserted into the tube 32 such that the plug 52 is adjacent to the tapered end 40 of the sleeve. The plug 52 is supported in the tool 50 between upper and lower support walls 54, 56 respectively. The interior 58 of the plug 52 is in fluid communication with the conduit 60 of the tool. A stem 62 is threaded at its lower end to engage a nut 64 whereby the lower wall 56 is drawn toward the upper wall 54 prior to insertion of the tool 50 into the sleeve 32. Hydraulic fluid is introduced at high pressure through the conduit 60 into the interior 58, causing the plug 52 to radially expand against the sleeve 32. After the initial plug expansion opposite the lower end of the sleeve 40, the tool 50 is raised one step approximately equivalent to a plug length, and the expansion is repeated. This process continues until the portion of the tube 36 is fully expanded. A suitable expansion plug material is polyether-urethane with a durmeter of 85±5, available as "Methane 1080" from Uniroyal, Inc. An applied fluid pressure of about 1,000 psi was found adequate for expanding the sleeve over portion 36.
After expansion of portion 36 is complete, the tool 50 is removed and another tool carrying the crimp plug 66 shown in FIG. 6 is inserted such that the plug 66 is centered about one inch above the sleeve lower edge 48. The hydraulic pressure is increased to about 2,000 psi, which is sufficient to form a crimp 34 within the desired size. As long as the crimp step is performed at least one inch above the sleeve edge 48, the edge will not recede from the tube wall. After the crimp is made, the tool is removed from the tube and the sleeve operation is complete.
The present invention does not require that the tool 50 be similar to that described immediately above. For example, a tool of the type generally described in the U.S. Pat. No. 4,069,573 issued on Jan. 24, 1978, to G. D. Rogers, Jr., et al, entitled "Method of Securing a Sleeve Within a Tube," could be adapted for use in the present invention. Similarly, it is not essential that hydraulic fluid be used as the pressure means by which the expansion is effected, although this has been found most convenient. Nor is it essential that an elastomer be used. If an elastomer is used, however, it is preferable that the inside and outside rims 68, 70 respectively be chamfered in order to accommodate the rim distortion resulting from pressurization. This feature provides a smooth outer plug surface and a better fluid seal along the rim surfaces during the expansion step.
The preferred embodiment of the invention having been described, it should be understood that the step of expanding the sleeve 32 over the region 36 is not necessary under all circumstances. Expanding the sleeve over the region 36 is required only when there is reason to believe that boiling may occur between the control rod 26 and the sleeve 32 if the annulus therebetween is too narrow. The unexpanded portion 72 of the sleeve is provided with a plurality of openings 46, 48 shown in FIGS. 2, 4 and 5. The openings permit coolant to exit the sleeve 32 and flush out any crud or other deposits that may accumulate in the annulus between the sleeve 32 and the tube 12. Thus, in reactors where the neutron flux is relatively low at the top of the active fuel, none of the sleeve 32 above the crimp 34 would require expansion against the tube 12. | A wear sleeve for a guide tube in a nuclear fuel assembly, and a method of installing the sleeve. The sleeve is an elongated metal cylinder having an upper portion adapted to be suspended from the upper end of the guide tube, and a lower portion adapted to be permanently deformed into interference fit with the walls of the guide tube whereby the sleeve may be secured against vertical movement. The method of installing the sleeve includes the steps of suspending the sleeve from the upper end of the guide tube, then expanding a selected lower surface of the sleeve until the sleeve is permanently deformed, whereby an interference fit between the sleeve and tube is formed. | 8 |
RELATED APPLICATIONS
[0001] This application claims priority under 35 U.S.C. §119(e) to co-pending U.S. Provisional Patent Application Ser. No. 61/463,764, filed 23 Feb. 2011.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The present invention relates to the field of hand-held clay target throwers and, specifically, to a clay target thrower comprising two main components that are each unique unto themselves and that both separately and upon combination, provide for a significantly improved hand-held clay target thrower system. The first main component is a unitary rear-loading flexible wire headend. The second component is a specially formed handle including a self-cocking block component and an impact structure to assist the comfortable, efficient, and effective throwing and launch of a clay target.
[0004] 2. Description of Related Art
[0005] Hand-held clay target throwers have been in use for well over a century, such that the prior art illustrates an on-going interest in developing and perfecting such clay target throwers. These prior art devices have taken many forms, but have in common a means for holding a clay target until a sufficient propelling force is applied to launch the clay target.
[0006] One conventional embodiment of a hand-held clay target thrower is described in U.S. Pat. No. 4,076,004 to Huelskamp. This device is a front-loading hand-held thrower for clay pigeons that is formed of a single piece of resilient plastic material. The headend portion of the device has arms with flanges which encircle the pigeon, engaging it on its outermost circumference. It is said that this device has no separately moving parts. The resilient plastic material forming the entirety of the device includes a flexible neck and arms that bend under pressure to release and launch a clay pigeon.
[0007] Many hand-held clay target throwers comprise multiple components, including a front-loading headend, a spring actuated launch mechanism, a handle, and other constituents which needlessly complicate manufacture and use of the devices. See e.g., U.S. Pat. No. 1,700,880 to Camp and U.S. Pat. No. 1,865,173 to Dickerman. Other clay target throwers require a multitude of components such as an additional pressure-releasable means to hold the clay target thrower in a cocked position prior to launch, see e.g., U.S. Pat. No. 4,233,952 to Perkins, or a spring to hold the clay target on the device prior to launch, see e.g., U.S. Pat. No. 934,093 to North.
[0008] U.S. Pat. No. 2,124,738 to Johnsen discloses a front-loading or side-loading wire headend and requires the use of a single continuous piece of metal to construct the entirety of the clay target throwing device to achieve a purported extraordinary simplicity arising from the complete lack of pivoting parts. U.S. Pat. No. 663,090 to Pike et al. discloses the use of a front-loading wire clip for use with a handle, wherein the wire component is bent to form a loop or loops to attach to the handle and act as a pivot point, such that the wire clip is capable of being turned to any desired angle relative to the handle or may be rigidly secured.
[0009] Accordingly, the prior art provides several examples of sub-optimal hand-held clay target throwers which, among other things: require too many components which frustrate their manufacture and use; eliminate inclusion of a pivot point which results in a loss of beneficial momentum to the clay target upon launch; require loading techniques that disrupt the smooth operation and function of the device and/or promote clay target or clay pigeon breakage, thus, increasing the cost of clay target shooting and decreasing user enjoyment; failing to produce variable flight patterns; and that make their productive and recreational use unnecessarily difficult by not including reliable or consistent self-cocking block and release or launch mechanisms.
BRIEF SUMMARY OF THE INVENTION
[0010] The present invention addresses problems not resolved by conventional hand-held clay target throwers by providing a clay target throwing device comprising two unique main components that, both separately and upon combination, provide for a significantly improved hand-held clay target thrower system. The first main component is a unitary rear-loading flexible wire headend. The second main component is a specially formed handle including a self-cocking block component and an impact backstop structure. Together the combined flexible wire headend and handle provide an easy-to-use, efficient, effective, comfortable, and weather-resistant hand-held self-cocking and controlled release clay target throwing unit. The present invention advantageously also permits a single user to both throw and shoot launched clay targets. The present invention is capable of throwing a clay target over 100 yards. The speed of the throw, depending on the skill of the thrower, is very fast and is directional. The present invention may be readily adapted for use by right-handed or left-handed throwers. The present invention gives a new dimension to the art of manual clay target throwing.
[0011] The Headend
[0012] The first main component is a unitary rear-loading flexible wire headend that is not only easier and faster to load but that also reduces clay target breakage. The flexible wire headend may comprise various metals and may be heat treated to give properties of flexibility and memory. For example, spring steel, piano wire, stainless steel, and any heat treated, galvanized, or zinc coated steel having sufficient flexibility and memory can be used. The flexible wire headend must be sufficiently stiff to accommodate the secure loading and throwing of the clay targets, but flexible enough to deflect under sufficient throwing force to allow a loaded clay target to launch from the clay target thrower.
[0013] In a preferred embodiment, a strong gauge wire, such as 3/16 inch steel rod, is used to provide proper bending. The flexible wire may comprise various diameters ranging between about 0.10 inches and about 0.50 inches, more preferably between about 0.11 inches and about 0.3 inches, still more preferably, between about 0.125 inches (⅛ inch) and about 0.250 inches (¼ inch) and, most preferably, at or between about 0.160 inches ( 4/25 inch) and about 0.192 inches (about ⅕ an inch). The headend wire is preferably treated to prevent rusting, for example, by the inclusion of zinc or by undergoing galvanization. It is also contemplated that the headend may be plated for aesthetic purposes, for example, to create a silver or gold appearance.
[0014] The flexible wire headend secures a loaded clay target by exerting flex pressure from the wire onto the loaded clay target. The top surface of the clay target is held by pressure exerted from the headend wire onto the shoulder of the clay target.
[0015] The flexible wire headend is uniquely adapted to permit rear-loading of a clay target. Advantageously, the user of the present invention can load the clay target into the clay target thrower while holding the device in the same position used to throw the clay target. That is, the user is provided with a means of direct rear-loading access that permits the user to maintain their grip on the handle in a throwing position while also accomplishing the easy and rapid rear-loading of a clay target. Rear-loading of the invention can also be referred to as top and rear-loading of the invention because the headend is oriented with its top-side facing upwards while a clay target is top and rear-loaded. Accordingly, the present invention advantageously does not require that the user turn the entire device around or on its side to accomplish loading of the clay target. Accordingly, a user of the present invention can rapidly load and launch a clay target. The present invention can be loaded and launched as fast as the shooter shoots. For example, the load and launch of three clay pigeons in three seconds can be accomplished using the present invention. In another example, an experienced thrower can load and throw each clay target in a series of several clay targets in about one second per clay target. Given the convenient, efficient and rapid loading and clay target deployment provided by the present invention, it enables a single user to load, launch, and shoot a clay target without additional assistance.
[0016] The flexible wire headend includes an attachment point bend partially enclosing an open space for attachment to the handle by means of inserting a rivet, or a nut and bolt, or similar means, through the partially enclosed open space. This attachment point also provides a pivot point around which the flexible wire headend may turn to the extent that the attachment point bend and its handle attachment, including a self-cocking block and an impact backstop structure, permit. In a preferred embodiment, the attachment point permits a fixed and preferred rotation range of about 135 degrees between the impact backstop structure and the self-cocking block component, however, greater or smaller fixed rotational ranges ranging from about 165 degrees to about 30 degrees, or, more preferably, between about 150 degrees and 60 degrees, may be accomplished. In a preferred embodiment, the internal radius of the open space partially enclosed by the attachment point bend is about ¼ inch.
[0017] In a preferred embodiment, the flexible wire headend spatially occupies a first (upper) horizontal plane and a second (lower) horizontal plane, which are connected by two separate left and right vertical connection bends in the flexible wire headend and united by an attachment point bend located on the second horizontal plane. Each of the first and second horizontal planes provide at least two points of contact with a top and bottom surface of a loaded clay target, respectively, which are used to hold a loaded clay target in place prior to launch. The flexible wire headend in the first horizontal plane provides two points of contact with opposing sides of the shoulder on the top surface of a loaded clay target. By securing the loaded clay target at points along its shoulder as opposed to its edge, the headend wire of the present invention advantageously facilitates reduced clay target breakage since the clay target shoulder provides a stronger point of contact to secure the loaded clay target. The flexible wire headend in the second horizontal plane provides two points of contact which generally provide support to, and contact with the bottom surface of, a loaded clay target.
[0018] In a preferred embodiment, the flexible wire headend is generally triangular in shape, and is open on one side. The overall shape of the second (lower) horizontal plane may be referred to “V-shaped” and can have an internal angle between the two lines extending out from the common axis of the “V” of about 44 degrees. The outer extremities of the “V-shaped” second (lower) horizontal plane of the flexible wire headend give rise to the two separate left and right vertical connection bends that each extend vertically upward from the second (lower) horizontal plane and then fold straight back along a first (upper) horizontal plane towards the handle of the device. Optionally, at least one of the left and right vertical connection bends may flare out to the side as part of the vertical rise, as depicted in FIGS. 1 to 5 , or such a flare out to the side may not be included.
[0019] In a preferred embodiment, the left and right extensions of the flexible wire headend folding back towards the handle of the device from the left and right vertical connection bends occupy the first (upper) horizontal plane. The left and right extensions occupying the first (upper) horizontal plane are straight and parallel in their respective horizontal plane to the wire lengths comprising the second (lower) horizontal plane. The left and right extensions are also angled outward and away (on their respective horizontal parallel plane) from the “V-shaped” second (lower) horizontal plane at an angle of about 22 degrees. Each of the left and right extensions occupying the first (upper) horizontal plane terminates by making a final loading bend at each end of the flexible wire headend that tilts upward and vertically away from both the first (upper) and second (lower) horizontal planes at an angle of about 35 degrees.
[0020] In a preferred embodiment, the flexible wire headend is about 6 inches long, as measured from the attachment point bend on the second (lower) horizontal plane and the two separate left and right vertical connection bends located on opposing ends of the “V-shaped” flexible wire headend (including about 0.6 inches in length to account for the formation of the attachment point bend); the maximum width of the flexible wire headend is about 5.1 inches (including one flare out to the side on one of the left and right vertical connection bends); the left and right vertical connection bends are about 0.9 inches high; and each of the loading bends contributes to an overall total vertical height of the flexible wire headend of about 1 inch.
[0021] In another embodiment, the flexible wire headend is about 6 inches long, as measured from the attachment point bend on the second (lower) horizontal plane and the two separate left and right vertical connection bends located on opposing ends of the “V-shaped” flexible wire headend (including about 2.0 to about 3.0 inches in length to account for the formation of the attachment point bend); the maximum width of the flexible wire headend is about 4.0 inches (not including one flare out to the side on one of the left and right vertical connection bends); the left and right vertical connection bends are about 0.8 inches high; and each of the loading bends contributes to an overall total vertical height of the flexible wire headend of about 1 inch. The flexible wire headend may also include an off-set bend that is about 0.19 inches high to further facilitate easy rear-loading of the headend by moving the headend away from any obstruction imposed by the handle. The overall shape of the second (lower) horizontal plane may be referred to “V-shaped” and can have an internal angle between the two lines extending out from the common axis of the “V” of greater than about 44 degrees, for example, between about 50 and about 110 degrees, more preferably between about 75 and about 90 degrees, and most preferably about 88 degrees.
[0022] In a preferred embodiment, when assembled together the handle and the flexible headend have a horizontal profile that is about 1¼ inch to about 1½ inch in height.
[0023] In its preferred embodiment, the headend system accommodates a variety of clay targets, or clay pigeons, which contributes to the versatility of the present invention. For example, it can be used to throw “standard” size clay targets. It may also be used to throw “nested” clay targets, which launches a standard clay target with a smaller clay target inside of it, a smaller “midi” placed into the back of the “standard” clay pigeon, a hard density “rabbit,” etc. Additionally, a three clay target nested set may all launch with a preferred embodiment of this invention. The headend system is, optionally, also computer designed for flexibility in using different configurations of the clay target.
[0024] While the above description defines a preferred embodiment, the inventors note that the flexible wire headend can vary in both shape and size, and to accommodate clay targets of varying size, in accordance with the general principles of this invention. That is, as new types of clay targets, pigeons, birds, or other clays are developed, the flexible wire headend can be modified or molded to accommodate the different targets. Such modification may involve the depression or the expansion of the flexible wire headend to accommodate the newly sized clay target.
[0025] With regard to the first (upper) horizontal plane of the flexible wire headend, in a particularly preferred embodiment, the unique headend configuration of the present invention also minimizes superfluous shoulder contact with the top surface of the clay target, thus further reducing unnecessary and disruptive friction between the clay target and the device upon clay target launch and also reducing clay target breakage. Specifically, the headend configuration provides two opposing straight flexible wire points of contact with the curved clay target shoulder on the top surface of the loaded clay target, as opposed to curved or otherwise continuous points of contact around, or that “hug,” the clay target shoulder.
[0026] The headend component preferably includes a fixed or stationary grommet that mounts on either one of the left or right vertical connection bends. The grommet is preferably made of rubber, but may also comprise other similarly suitable materials. The, preferably, fixed and stationary rubber grommet serves multiple purposes. Upon loading, the rubber grommet provides a stopping point such that the user loads a clay target until it comes into contact with the rubber grommet. Upon launch, contact of the clay target against the rubber grommet initiates and facilitates the rotational spin of the clay target. Advantageously, the rubber grommet may be used on either of the left or right vertical connection bends to accommodate usage of the present invention by either left-handed or right-handed throwers. A non-fixed or rolling rubber grommet is not contemplated for use with the present invention because it would not generate the desired clay target rotation upon clay target launch.
[0027] In another embodiment, the flexible wire headend can be modified to include more bends to accommodate multiple clay targets. For example, three bends could be included to accommodate nested clay pigeons, batue, and large and small rabbit targets.
[0028] In another embodiment, the flexible wire headend can be bent with an off-set to further facilitate easy loading by the reduction or elimination of the handle from being an obstruction.
[0029] In yet another embodiment, the present invention can include a flexible wire headend adapted for use with various projectiles, including, but not limited to, tennis balls, baseballs, flying disks, etc.
[0030] The Handle
[0031] The second component is a specially formed handle including a self-cocking block component and an impact structure to assist the comfortable, efficient, consistent, reliable, controlled, and effective throwing and launch of a clay target. Specifically, the present invention provides an ergonomic handle that is not only comfortable to use, but also permits the user to manipulate the clay target thrower to produce multiple flight patterns.
[0032] The preferred embodiment includes a round ergonomic handle, but the handle may comprise a variety of shapes and sizes. In an especially preferred embodiment, the handle is round and tapered, with the widest part of the handle forming the end of the handle. The handle of the present invention permits the user to swing the clay target thrower closer to the ground as the thrower can grasp the handle closer to the headend.
[0033] The handle can comprise polymeric materials, including but not limited to, a copolymer of acrylonitrile, butadiene, and styrene (an ABS plastic), polyvinyl chloride (PVC), co-polyester, aluminum, steel, etc., or suitable combinations thereof. In one embodiment, the handle is made from a formulation of polymers that provide added strength and flexibility. This handle was engineered to give maximum form, fit, and function required by its design. The handle is preferably injection molded and may comprise clam shell injection molding. The handle can be formed of two components, for example, as depicted in FIGS. 6 and 7 . These two components are preferably secured together by an adhesive, such as glue or another similarly suitable material.
[0034] The handle length can vary in size between about 10 inches and about 42 inches, and its diameter can vary from about 1 inch to about 2 inches, and is preferably about 1.2 inches. In a particularly preferred embodiment, the handle length is about 16½ inches and the handle diameter is about 1⅛ inch to about 1¼ inch at its end.
[0035] In an alternative embodiment, the handle of the present invention is made out of conduit size metal and is about ½ inch to about ⅝ inches in diameter.
[0036] Separate parts of the handle and wire headend system come together to create a pivot point to allow for greater speed and longer distances of launched clay targets. In one embodiment, the headend component and the handle component are joined together using a bolt and nut, or rivet, or a similar attachment means, and tightened to specification. In a preferred embodiment, the attachment means used to form the pivot point of the present invention does not also function to secure the two separate handle components, which are, instead, adhered together by an adhesive.
[0037] The pivot point may be used to activate the locking of a loaded clay target, cocking, and launching of a clay target within and from the present invention. The cocking motion is automatic with the back swing and requires no separate operation. Specifically, the handle of the present invention facilitates automatic cocking by inclusion of a pivot rotation block component that stops the continued rotation of the headend upon swinging the clay target thrower backwards prior to clay target launch. The pivot rotation block component may be integrally formed as part of the handle itself, or may comprise a separate component, such as a bolt or rivet, or other suitable means.
[0038] The handle also includes a backstop structure on one end, or its tip, that distributes impact force over a broad area of the handle. This distribution of impact force prevents material fatigue of both the handle and the flexible wire headend at the impact surfaces to give the clay target thrower a long life. When the wire headend system impacts the handle's impact backstop structure at the end of the throw, the force and momentum of the throw transfers to the clay target to launch the clay target from the headend of the clay target thrower outward from the headend of the clay target thrower. The combined flexible wire headend and handle also provide an assembly that is comfortable to use as the clay target thrower includes an impact backstop structure on the handle that stops the forward motion of the headend to activate clay target launch, that also absorbs and distributes and disperses the impact force of the clay target launch throughout the handle. The backstop structure may be integrally formed as part of the handle itself, or may comprise a separate component or components, such as a nut and bolt, or rivet, or other suitable means. In one preferred embodiment, the impact backstop structure comprises a nut and bolt or rivet. In another preferred embodiment, the impact backstop structure comprises a bolt or rivet together with material integrally formed as part of the handle, which together serves to absorb the impact and distribute the impact force throughout the handle.
[0039] The handle may include features to aid the user's grip and for non-slip functionality, such as cross-hatching, dipping in a substance to improve the tactile feel and/or grip (such as rubber or a similar substance), a knob on the handle, etc.
[0040] In a preferred embodiment, the handle is a round ergonomic handle that allows for a number of different clay target throws and is, optionally, computer designed. The round handle fits specifications required to throw a clay target in various patterns. That is, the round handle is easily gripped at various locations and readily accommodates unique angles of launch to give the thrower the ability to control the angles, direction, and speed of a thrown clay target. For example, the launched clay pigeon can be maneuvered left, right, straight up, left sharp left 90 degrees throw and right sharp right 90 degrees, up and back at the thrower, low and straight away, down and high speed sail, to provide a soft floater of variable speed, and others.
[0041] The handle may optionally include a switch for turning an integrated, attached, or otherwise associated light-emitting diode (LED) light on and off, may include color variations, such as green with a fluorescent additive, may include a designated surface space for a logo, and may be adapted to include a lanyard for hanging the clay target thrower from the user's wrist when it is not in use.
[0042] The handle may also be hollow and may be adapted to accommodate storage of various items including, but not limited to, batteries with a light-emitting diode (LED) bulb to light or activate a glow-in-the-dark paint on a clay target for night shooting and/or personal items, such as a cigar, fire starter, beverage, etc.
[0043] In one embodiment, the handle includes an integrated LED light to be used with light activated painted clay targets. That is, the clay target is painted with glowing type paint. Paint might be lighted before launch. In such an embodiment, batteries in the handle would be attached to an LED light at the handle's end to generate the light source through a 16 light gauge wire (or a 16 light gauge to a 20 light gauge wire), or whatever wire is chosen. This unique embodiment allows for night throwing activities involving specially treated or painted clay targets.
[0044] In an alternative embodiment, the handle may include an additional pivot point to provide the user with another action for greater throwing power to achieve greater distances and/or control.
[0045] Based on the disclosure provided herein, the inventors aim to bring to market a new concept to the hand-held clay target throwing devices category. A handle product, or component, preferably utilizes polymers and a special flexible wire headend system configuration product, or component. This new device and system allows for throwing various patterns and types of clay targets. The exclusive rear-loading flexible wire headend design is unique and gives speed in throwing. It also reduces the clay target problem of breakage while loading. This unique headend design also accommodates multiple types and configurations of clay targets, such as a single full-sized clay target, and nested, ground roll, and mini clay targets. The handle and the headend products, or components, may be high tech in design and provide ergonomic function.
[0046] Using the Present Invention
[0047] The operational technique for using the present invention is similar to throwing a football—slightly side arm. The stance is very similar to that of a quarterback preparing for a long throw with his feet slightly spread. The forward motion and release is nearly the same as the quarterback. The user loads the clay target into the headend load rails from the rear. That is, the user holds the clay target thrower and inserts a clay target into the back of the wire form from the handle. The clay target is pushed forward until it comes in contact with, or is seated against, the rubber grommet. The user does not need to push hard or push further than the rubber stop. The user swings the clay pigeon thrower back behind them (about 45 degrees back from their hip) to initiate the throw.
[0048] Upon extending the throwing arm backwards, the clay target thrower should be kept at a level that is about waist high. This backward movement “cocks” the thrower automatically due to the rotational pivot of the headend against the rotation block component. When “cocked,” the headend preferably will be about 135 degrees to the handle. The user then starts a forward movement, for example, in a slightly side arm throwing position, extending their arm from behind to a position in front of them, resulting in a rotation of the position of the clay target thrower handle of about 180 degrees. As the thrower's arm moves forward, the elbow is kept close to the hip and waist, and after rotating through a range of about 180 degrees, the thrower stops their forward motion, causing the gathered momentum to allow the flexible wire headend form to “snap” forward rotating the loaded clay target around the pivot point on the handle about 135 degrees to contact the impact backstop structure which, upon contact exerts sufficient pressure to release and launch the clay target from the holding pressure exerted by the flexible wire headend. Accordingly, the rotational force of the user's 180 degree throw is bolstered by the additional 135 degrees of rotation provided by the pivot mechanism of the present invention to produce a more powerful throw.
[0049] As the clay target hits the, preferably, fixed or stationary rubber grommet it starts to spin and releases from the loading bend extensions. The release point normally is about 180 degrees from the back swing. The impact backstop structure automatically stops the headend swing as the thrower stops their arm after the about 180 degree launch swing. Depending on the user's technique, a variety of throws can be generated. As the clay pigeon races out very fast, a distance of over 100 yards can be achieved. Variations of holding the handle results in being able to launch some challenging targets, and use of a preferred round handle enables the thrower to hold the handle at any angle relative to the headend component, resulting in endless throwing possibilities. The user simply must stop the forward motion of their throw to overcome the flex tension within the flexible wire headend and launch a clay target from the clay target thrower. Forward motion launches the clay target in any angle or elevation. Moving the position of the hand on the handle can create various types of throwing angles. Straight away low, high, or in between gives you different angles and direction. Nested clays will drop out at 25-30 yards and high speed ground huggers will sail over 100 yards.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
[0050] The accompanying Figures, which are incorporated in and constitute a part of this specification, illustrate various exemplary embodiments.
[0051] FIG. 1 provides a bottom elevation view of a clay target thrower according to the present invention.
[0052] FIG. 2 provides a top elevation view of a flexible wire headend according to the present invention.
[0053] FIG. 3 provides a side elevation view of a flexible wire headend along a horizontal plane according to the present invention.
[0054] FIG. 4 provides a front-end elevation view of a flexible wire headend along a vertical plane according to the present invention.
[0055] FIG. 5 provides a top elevation view of a flexible wire headend including a fixed or stationary rubber grommet and additionally indicating the fit of an exemplary clay pigeon according to the present invention.
[0056] FIG. 6 provides an exploded perspective view of a handle according to the present invention.
[0057] FIG. 7 provides an assembled perspective view of a handle according to the present invention.
[0058] FIG. 8 provides a side elevation view and close up of the connection between the headend and the handle according to the present invention as generally shown in FIGS. 1-7 .
[0059] FIG. 9 provides a top perspective view of another embodiment of the present invention.
[0060] FIG. 10 provides a front elevation view of the embodiment depicted in FIG. 9 with an interior view of the pivot point, including the rotation block component and the impact structure.
[0061] FIG. 11 provides a side elevation view of the embodiment depicted in FIGS. 9 , 10 , and 12 with an interior view of the pivot point, including the rotation block component and the impact structure.
[0062] FIG. 12 provides a back perspective view of the embodiment depicted in FIGS. 9-11 with an interior view of the pivot point, including the rotation block component and the impact structure.
[0063] FIG. 13 provides a side perspective view of another handle embodiment according to the present invention.
[0064] FIG. 14 provides a top elevation view of a clay target thrower according to the present invention.
DETAILED DESCRIPTION OF THE INVENTION
[0065] Although the disclosure hereof is detailed and exact to enable those skilled in the art to practice the invention, the physical embodiments herein disclosed merely exemplify the invention which may be embodied in other specific structures.
[0066] FIG. 1 provides a bottom elevation view of a clay target thrower 10 according to the present invention. Clay target thrower 10 generally comprises a flexible wire headend 20 and a handle 60 . As depicted, flexible wire headend 20 includes a first (upper) horizontal plane 28 and a second (lower) horizontal plane 22 . The support wire lengths 24 and 26 of the second horizontal plane 22 provide contact points to support the loaded clay target. Loading wire lengths 30 and 32 of the first horizontal plane 28 provide contact points to hold the loaded clay target at the shoulder. Loading bend extensions 34 and 36 tilt upward and vertically away from both the first (upper) and second (lower) horizontal planes at an angle of about 35 degrees and aid loading of the clay target thrower. Rubber grommet 38 is depicted on the left vertical connection bend 40 (vertical depth not visible) that extends vertically upward from the second (lower) horizontal plane and then folds straight back towards the handle of the device. As depicted, vertical connection bend 42 comprises a flare out to the side 48 . In an alternative embodiment, rubber grommet 38 can be placed on the right vertical connection bend 42 (vertical depth not visible) that extends vertically upward from the second (lower) horizontal plane and then folds straight back towards the handle of the device.
[0067] Handle 60 is depicted as being generally circular or round in its circumference and bearing a cross-hatch grip 62 on a portion of its surface. Handle 60 is also depicted with a pivot connection means (such as a bolt and nut, or rivet) 64 inserted through the attachment point bend (not visible) of headend 20 . Handle 60 further depicts the inclusion of a separate handle contact means (such as a bolt and nut, or rivet) 66 that serves as part of the handle impact backstop structure 68 .
[0068] FIG. 2 provides a top elevation view of a flexible wire headend 20 according to the present invention. As depicted, flexible wire headend 20 includes a first (upper) horizontal plane 28 and a second (lower) horizontal plane 22 . The support wire lengths 24 and 26 of the second horizontal plane 22 provide contact points to support the loaded clay target. Loading wire lengths 30 and 32 of the first horizontal plane 28 provide contact points to hold the loaded clay target at the shoulder. Left and right vertical connection bends 40 and 42 (vertical depth not depicted) extend vertically upward from the second (lower) horizontal plane and then fold straight back towards the handle (not depicted) along the first (upper) horizontal plane 28 of the device. As depicted, vertical connection bend 42 comprises a flare out to the side 48 . Loading bend extensions 34 and 36 tilt upward and vertically away from both the first (upper) and second (lower) horizontal planes at an angle of about 35 degrees and aid loading of the clay target thrower. Attachment point bend 44 is depicted as defining an end opening space 46 .
[0069] FIG. 3 provides a side elevation view of a flexible wire headend 20 along a horizontal plane according to the present invention. As depicted, flexible wire headend 20 includes a first (upper) horizontal plane 28 and a second (lower) horizontal plane 22 . The support wire lengths 24 (not visible) and 26 of the second horizontal plane 22 provide contact points to support the loaded clay target. Loading wire lengths 30 and 32 (not visible) of the first horizontal plane 28 provide contact points to hold the loaded clay target at the shoulder. Left and right vertical connection bends 40 and 42 extend vertically upward from the second (lower) horizontal plane and then fold straight back towards the handle (not depicted) along the first (upper) horizontal plane 28 of the device. Loading bend extensions 34 (not visible) and 36 tilt upward and vertically away from both the first (upper) and second (lower) horizontal planes at an angle of about 35 degrees and aid loading of the clay target thrower. Attachment point bend 44 is depicted.
[0070] FIG. 4 provides a side elevation view of a flexible wire headend 20 along a vertical plane according to the present invention. As depicted, flexible wire headend 20 includes a first (upper) horizontal plane 28 and a second (lower) horizontal plane 22 . The support wire lengths 24 and 26 of the second horizontal plane 22 provide contact points to support the loaded clay target. Loading wire lengths 30 and 32 (neither visible) of the first horizontal plane 28 provide contact points to hold the loaded clay target at the shoulder. Left and right vertical connection bends 40 and 42 extend vertically upward from the second (lower) horizontal plane 22 and then fold straight back towards the handle (not depicted) along the first (upper) horizontal plane 28 of the device. As depicted, vertical connection bend 42 comprises a flare out to the side 48 . Loading bend extensions 34 and 36 tilt upward and vertically away from both the first (upper) and second (lower) horizontal planes at an angle of about 35 degrees and aid loading of the clay target thrower. Attachment point bend 44 is depicted.
[0071] FIG. 5 provides a top elevation view of a flexible wire headend 20 including a rubber grommet and additionally indicating the fit of an exemplary clay pigeon in broken line according to the present invention. As depicted, flexible wire headend 20 includes a first (upper) horizontal plane 28 and a second (lower) horizontal plane 22 . The support wire lengths 24 and 26 of the second horizontal plane 22 provide contact points to support the loaded clay target. Loading wire lengths 30 and 32 of the first horizontal plane 28 provide contact points to hold the loaded clay target at the shoulder. Loading bend extensions 34 and 36 tilt upward and vertically away from both the first (upper) and second (lower) horizontal planes at an angle of about 35 degrees and aid loading of the clay target thrower. Rubber grommet 38 is depicted on the left vertical connection bend 40 (vertical depth not visible) that extends vertically upward from the second (lower) horizontal plane and then folds straight back towards the handle of the device. In an alternative embodiment, rubber grommet 38 can be placed on the right vertical connection bend 42 (vertical depth not visible) that extends vertically upward from the second (lower) horizontal plane and then folds straight back towards the handle of the device. As depicted, vertical connection bend 42 comprises a flare out to the side 48 .
[0072] FIG. 6 provides an exploded perspective view of a handle 60 according to the present invention. As depicted, the handle is shown to comprise two parts, a first part 70 and a second part 72 . The handle 60 includes on its external surfaces a cross-hatch grip 62 , and has a hollow interior 84 . The first part 70 of handle 60 includes two holes 74 and 76 to provide access to connection means (such as a bolt and nut, or rivet) 64 (not depicted) to unite the first part 70 of handle 60 to the second part 72 of handle 60 and to attach a contact means (such as a bolt and nut, or rivet) 66 (not depicted). The second part 72 of handle 60 include two holes 78 and 80 to provide access to connection means (such as a bolt and nut, or rivet) 64 to unite the second part 72 of handle 60 to the first part 70 of handle 60 and to attach a contact means (such as a bolt and nut, or rivet) 66 . The first part 70 and the second part 72 of handle 60 also include an open interior pivot space 82 . The hole 74 of the first part 70 of handle 60 and the hole 78 of the second part 72 of handle 60 are located within the space defining open interior pivot space 82 . An impact backstop structure 68 is shown to define the interior boundary of the open interior pivot space 82 , with its upper portion contacting the exterior of the contact means (such as a bolt and nut, or rivet) 66 assembly. The cocking block 88 is shown to comprise the lower edge of the space defined by the open interior pivot space 82 .
[0073] FIG. 7 provides an assembled perspective view of handle 60 according to the present invention and as detailed above in connection with FIG. 6 . The cocking block 88 is shown to comprise the lower edge of the space defined by the open interior pivot space 82 .
[0074] FIG. 8 provides a side elevation view and close up of the connection between the headend 20 and the handle 60 according to the present invention, as generally shown in FIGS. 1-7 . The attachment point bend 44 of headend 20 is shown to fit within the open interior pivot space 82 of handle 60 . The first part 70 and second part 72 of handle 60 are shown as assembled. Specifically, a connection means (such as a bolt and nut, or rivet) 64 is shown to be inserted through hole 74 of the first part 70 of handle 60 , through the end opening space provided by the attachment point bend of headend 20 , and into hole 78 of the second part 72 of handle 60 . A separate contact means (such as a bolt and nut, or rivet) 66 is shown to be inserted through hole 76 of the first part 70 of handle 60 and into hole 80 of the second part 72 of handle 60 . The contact means 66 does not occupy the open interior pivot space 82 of handle 60 , and the impact backstop structure defines the interior boundary of the open interior pivot space 82 that includes an outer surface of contact means 66 . Off-set bend 86 of headend wire 20 depicts an optional embodiment of headend 20 which includes off-set bend 86 to further facilitate easy rear-loading of the headend 20 by moving the headend 20 away from any obstruction imposed by the handle 60 . The cocking block 88 is shown to comprise the lower edge of the space defined by the open interior pivot space 82 .
[0075] FIG. 9 provides a top perspective view of a clay target thrower 200 according to the present invention. Clay target thrower 200 is similar to the device depicted in FIGS. 1-8 and the descriptions for the shared reference numbers provided for FIGS. 1-8 are incorporated herein by reference. Here, however, the flexible wire headend 220 differs in that it does not include the flare out to the side 48 depicted on vertical connection bend 42 in FIGS. 1-5 , and the wire comprising attachment point bend 44 (not depicted) and the support wire of the second horizontal plane 22 (not depicted) differ as shown in FIGS. 10-12 .
[0076] FIG. 10 provides a front elevation view of the embodiment 200 depicted in FIGS. 9 , 11 , and 12 with an interior view of the pivot point, including the rotation block component 88 and the impact backstop structure 68 , including a contact means (such as a bolt and nut, or rivet) 66 that serves as part of the handle impact backstop structure 68 . Apart from differences in the wire headend 220 as described and depicted in FIGS. 9 , 11 , and 12 , the clay target thrower 200 is similar to the device depicted in FIGS. 1-8 and the descriptions for the shared reference numbers provided for FIGS. 1-8 are incorporated herein by reference.
[0077] FIG. 11 provides a side elevation view of the embodiment 200 depicted in FIGS. 9 , 10 , and 12 with an interior view of the pivot point, including the rotation block component 88 and the impact backstop structure 68 , including a contact means (such as a bolt and nut, or rivet) 66 that serves as part of the handle impact backstop structure. The off-set bend 86 to further facilitate easy rear-loading of the headend 220 by moving the headend 220 away from any obstruction imposed by the handle 60 is also shown. The off-set bend 86 is shown to elevate the loading surface to a horizontal plane that is approximately equal to the top surface of the handle 60 . Apart from differences in the wire headend 220 as described and depicted in FIGS. 9 , 11 , and 12 , the clay target thrower 200 is similar to the device depicted in FIGS. 1-8 and the descriptions for the shared reference numbers provided for FIGS. 1-8 are incorporated herein by reference.
[0078] FIG. 12 provides a back perspective view of the embodiment depicted in FIGS. 9-11 , including the rotation block component and the impact backstop structure 68 , including a contact means (such as a bolt and nut, or rivet) 66 that serves as part of the handle impact backstop structure 68 . The wire headend 220 additionally includes wire length 50 (of wire portion 24 ) and wire length 52 (of wire portion 26 ) which each extend outward from the off-set bend 86 in a straight length before extending outwards laterally in a “V-shape.” That is, the shape of the second (lower) horizontal plane may be referred to as “V-shaped” and includes two straight wire extensions. The “V-shaped” portion of the second (lower) horizontal plane has an internal angle between the two lines extending out from the common axis of the “V” of about 88 degrees. Apart from differences in the wire headend as described and depicted in FIGS. 9-11 , the clay target thrower 200 is similar to the device depicted in FIGS. 1-8 and the descriptions for the shared reference numbers provided for FIGS. 1-8 are incorporated herein by reference.
[0079] FIG. 13 provides a side perspective view of an alternative handle embodiment according to the present invention. As depicted, the handle 160 is round and cross-hatched 62 for non-slip gripping and is about 1 inch in diameter, and has a length of about 12 inches (1 foot). It is constructed of a high impact and light weight polymer material and is ergonomically designed for throwing variations. The handle includes an alternative design for the impact backstop structure 168 which comprises the upper end of handle 160 .
[0080] FIG. 14 provides a top elevation view of an alternative embodiment of a clay target thrower 300 according to the present invention. FIG. 14 depicts headend 20 substantially as presented in FIG. 5 . FIG. 14 , however, depicts the headend connected to an alternative embodiment of handle 60 . As depicted, the handle includes a single connection means (such as a bolt and nut, or rivet) 64 and impact backstop structure 68 is integrally formed as part of handle 60 . Apart from differences in the impact backstop structure 68 , the clay target thrower 300 is similar to the device depicted in FIGS. 1-8 and the descriptions for the shared reference numbers provided for FIGS. 1-8 are incorporated herein by reference.
[0081] While the inventors have disclosed the preferred embodiments of their clay target thrower invention, they do not confine themselves to any particular form of the flexible wire headend to grip the clay target, and the flexible wire headend may be bent in any desired manner to form a flexible grip to secure a clay target. Additionally, the handle may take on various forms without deviating from the spirit of this invention. | The present invention addresses problems not resolved by conventional hand-held clay target throwers by providing a clay target throwing device comprising two unique main components that, both separately and upon combination, provide for a significantly improved hand-held clay target thrower device. The first main component is a unitary rear-loading flexible wire headend. The second main component is a specially formed handle including a self-cocking block component and an impact backstop structure. Together the combined flexible wire headend and handle provide an easy-to-use, efficient, effective, comfortable, and weather-resistant hand-held self-cocking and controlled release clay target throwing unit. | 5 |
CROSS REFERENCE TO RELATED APPLICATIONS
The present application is a divisional of co-pending U.S. application Ser. No. 10/931,561, filed Aug. 31, 2004, which claims priority to European patent application No. 03077819.5, filed Sep. 8, 2003, which are both hereby incorporated by reference as if fully disclosed herein.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The invention relates to a covering for an architectural opening, such as a roller shade for a window, having one or more, vertically-extending parallel layers of shade material. This invention especially relates to a roller shade, to which front and rear layers of a shade material are attached, so that the layers can be moved parallel to one another to open and close the shade to light.
2. Description of the Relevant Art
Architectural coverings are known with two vertically-extending parallel sheet layers, which are disposed one in front of the other and each of which has an array of elongated, longitudinally-extending, vertically-alternating transparent and opaque stripes. When the transparent stripes of one layer have been in vertical alignment with the transparent stripes of the other layer, light has been transmitted through the coverings, but when the opaque stripes of one layer have been vertically aligned with the transparent stripes of the other layer, these coverings have blocked light. See GB 926 663, GB 1 227 619, U.S. Pat. No. 2,029,675, FR 1 366 224, DE 2 326 438, NL 7209084 and U.S. Pat. No. 6,189,592.
The two vertically-extending layers of such coverings have been made of fabric, plastic or the like and have been connected at their top and/or bottom ends by top and/or bottom bars. A special fabric, very suitable for such coverings, has been described in EP 1 088 920 and EP 1 241 318. This fabric is a two layer woven fabric having one or more binder threads connecting the layers, so that one layer could slide along the binder threads and along the other layer.
Such double layer architectural coverings have been made as roller shades, having a roller to which the layers of shade materials have been attached at radially different locations of the roller, so that partial rotation of the roller has displaced the layers relative to each other and continued rotation has wound the layers about the roller. The layers of shade materials of roller shades have generally been attached to their rollers by folding each layer over an attachment member or rod and then sliding or pushing the attachment member with the layer folded over it into a groove or slit of the roller. See GB 19 449 and DE 25 19 365.
However, the use of an attachment member has proven unsatisfactory for attaching a layer of a shade material to a roller. If the shade material has not been well aligned with the roller when folded over its attachment member, the shade has not hung straight down from the roller and has not operated well. Also, the layer folded over the attachment member has sometimes tended to get out of alignment during assembly of the roller shade which has been hard to correct afterwards. With two layer roller shades, it has been particularly difficult to align the complementary patterns, typically stripes of the front and rear layers, using such attachment members. Also, the layers have tended to become skewed, relative to one another, when wound about the roller if both layers have not been perfectly aligned with the roller. When the layers have not been perfectly aligned, light has shone through gaps between the stripes, and the patterns have no longer appeared to be complimentary.
SUMMARY OF THE INVENTION
In accordance with this invention, an architectural covering, such as a roller shade, is provided which includes a vertically-extending layer of a shade material between an elongated longitudinally-extending roller and an elongated longitudinally-extending bar; an elongated groove extending longitudinally along the length of the outer surface of the roller; a top portion of the layer of shade material being attached to an elongated longitudinally-extending top attachment member in the groove; the layer of shade material extending longitudinally along the roller, so that partial rotation of the roller causes the layer to move vertically and continued rotation of the roller winds the layer around the roller, and wherein:
the outer surface of the top attachment member has at least two peaks along its length such that when the upper portion of the layer of the shade material is attached to the attachment member, the peaks extend through the upper portion of the layer, preferably through an open structured section of the top portion of the layer.
Advantageously, the shade material comprises a plurality of vertically-extending layers, especially front and rear layers, the outer surface of the roller comprises a plurality of radially spaced apart grooves, and a top portion of each layer is attached to a different attachment member in a different groove, especially front or rear groove. Also advantageously, a bottom portion of each layer of the shade material is also attached to an elongated longitudinally-extending bottom attachment member in an elongated longitudinally-extending slit in the bar; the outer surface of the bottom attachment member having at least two peaks along its length such that when the bottom portion of the layer of shade material is attached to the bottom attachment member, the peaks extend through the bottom portion of the layer, preferably through an open structured section of the bottom portion of the layer. It is particularly advantageous that the shade material comprises front and rear layers, each with an array of elongated, longitudinally-extending, vertically-alternating transparent and opaque stripes.
BRIEF DESCRIPTION OF THE DRAWINGS
Further aspects of the invention will be apparent from the detailed description below of particular embodiments and the drawings thereof, in which:
FIG. 1 is a schematic perspective view of a roller shade with a double layer shade material extending between an elongated roller and an elongated bottom bar;
FIG. 2 is a cross-section of the shade of FIG. 1 , showing the attachment of the shade material to the roller and bottom bar;
FIG. 3A-3D is a schematic representation of the attachment of a first embodiment of an elongated attachment member to one of the layers of a woven fabric shade material and the subsequent attachment of the attachment member to an elongated groove in the roller;
FIGS. 4A-4C is a schematic representation of the attachment of two layers of the woven fabric shade material together to the first embodiment of the attachment member prior to attaching the attachment member to the bottom bar;
FIGS. 5A-5E are schematic perspective views of alternative embodiments of the attachment members; and
FIGS. 6A-6C are schematic perspective views, like FIGS. 3A-3C , of the attachment of the attachment member of FIG. 5D to a non-woven shade material.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIGS. 1 and 2 show a roller shade or blind 1 of the invention having an elongated longitudinally-extending roller 3 at its top, a two-layer vertically-extending shade material or covering 5 , an elongated longitudinally-extending bar or rail 7 at its bottom and means 9 for rotating the roller 3 to raise and lower the shade material and the bar to open and close the shade (e.g., a conventional manually operated ball-chain or endless cord). The roller 3 is preferably a conventional hollow tube-like profile extending between a left end 11 and a right end 13 . The outer surface 3 A of the roller has and an elongated longitudinally-extending front groove 15 and an elongated longitudinally-extending rear groove 17 . The front and rear grooves 15 , 17 are radially spaced apart along the outer surface 3 A of the roller and are preferably undercut grooves. In this regard, each groove 15 , 17 has a longitudinally-extending top slit 19 , 21 in communication with a laterally larger, interior top pocket 19 A, 21 A. The top pocket 19 A, 21 A of each groove 15 , 17 can hold an elongate, longitudinally-extending top attachment member 23 , 25 , so that the top attachment members cannot fall out through the top slits 19 , 21 while the shade material 5 , attached to the top attachment members, extends downwards from the grooves.
The shade material 5 includes a vertically-extending front layer 27 and a vertically-extending rear layer 29 . When the shade material 5 is assembled to the roller 3 , the front layer 27 extends downwardly from the slit 19 of the front groove 15 , and the rear layer 29 extends downwardly from the slit 21 of the rear groove 17 . The front layer 27 has a plurality of elongate longitudinally-extending parallel rectangular stripes 31 , 33 . Relatively opaque stripes 31 alternate with relative translucent stripes 33 . The rear layer 29 also has a plurality of elongate longitudinally-extending parallel rectangular stripes 35 , 37 which are alternating relatively opaque stripes 35 and relatively translucent stripes 37 . The rear layer 29 can be moved vertically relative to the front layer 27 , so that the opaque stripes 31 , 35 of both layers can be aligned with each other or with the translucent stripes 33 , 37 of the opposite layer. Such movement of one layer relative to the other can be used to control and vary the light-transmitting properties of the shade 1 .
The top portions 39 , 41 of the front and rear layer 27 , 29 of the shade material 5 are attached to the front and rear top grooves 15 , 17 of the roller 3 , using the front and rear, top attachment members 23 , 25 . The manner of attaching the layers to the top attachment members is described below in relation to FIGS. 3 and 4 .
The bar 7 is preferably a generally U-shaped profile extending between a left end 43 and a right end 45 . The bar ( 7 ) has a front wall 47 , a rear wall 49 and a bottom wall 51 with an upwardly open, elongate, longitudinally-extending bottom slit 53 that opens into an interior space 55 in the bar. The bottom slit 53 extends along the entire length of the bar 7 , and the shade material 5 is attached to the bar 7 and extends upwardly from the bottom slit 53 towards the roller 3 . At the top of the front wall 47 of the bar 7 is an elongate longitudinally-extending interior undercut bottom pocket 57 , adjacent the bottom slit 53 . The bottom pocket 57 has a downwardly open, elongate, longitudinally-extending mouth 59 which is laterally smaller than the bottom pocket. Preferably, the bottom pocket 57 is integrally formed with the front wall 47 of the bar 7 . The layers 27 , 29 of the shade material 5 , mounted on the bar 7 , extend downwardly from the mouth 59 of the bottom pocket 57 into the interior space 55 of the bar and then upwardly through the bottom slit 53 towards the roller 3 .
As best shown in FIG. 2 , the top portion 39 of the front layer 27 of the shade material 5 is held by the front top attachment member 23 in the top pocket 19 A of the front top groove 15 of the roller 3 , and the top portion 41 of the rear layer 29 of the shade material is held by the rear top attachment member 25 in the top pocket 21 A of the rear top groove 17 of the roller. Also, front and rear bottom portions 61 , 63 of the front and rear layers 27 , 29 of the shade material 5 are attached to a bottom attachment member 65 in the bottom pocket 57 in the bar 7 . Preferably, the rear layer 29 of the shade material is longer than the front layer 27 , and when the bottom portions 61 , 63 of the two layers are mounted in the bottom pocket 57 , a loop 67 is formed in the rear layer 29 in the interior space 55 of the bar to serve as a hammock for a ballast rod 69 . The ballast rod 69 serves to pull the shade material taut and to help keep its layers aligned during operation of the shade 1 .
The top and bottom attachment members 21 , 23 , 65 with the shade material 5 attached to them are preferably slid into the top and bottom pockets pockets 19 A, 21 A, 57 from the right or left ends 11 , 13 , 43 , 45 of the roller 3 and bar 7 . The left and right ends of the roller and bar can then be closed by a suitable end cap (not shown).
Partial clockwise rotation of the roller 3 , as shown in FIG. 2 , by the operating means 9 , will move the front and rear layers 27 , 29 relative to each other, for example, to align either the opaque stripes of both layers, or the opaque stripes of each layer with the translucent stripes of the opposite layer. The front and rear top grooves 15 , 17 will move clockwise, and the rear layer 29 will be lifted a small distance, causing the loop 67 in the rear layer to move upwards within interior space 55 of bar 7 with ballast rod 69 . The small distance can be the vertical height of a stripe 35 , 37 of the rear layer 29 , thereby causing the opaque stripes 31 , 35 of both layers 27 , 29 to align or the opaque stripes 35 of the rear layer 29 to align with the translucent stripes 33 of the front layer. Continued clockwise rotation of the roller 3 will further lift the loop 67 and ballast rod 69 into abutment with the front and rear walls 47 , 49 of the bar 7 , near the bottom slit 53 . If such clockwise rotation is continued, the front and rear layers 27 , 29 of the shade material 5 will be wound about the roller 3 , thereby lifting the bar 7 upwardly. Thereafter, counter clock wise rotation will move the front and rear top grooves counter clockwise, causing the shade material to be unwound and the bar to be lowered. When the shade material is unwound and the counter clockwise rotation continues, the rear layer 29 will move again relative to the front layer 27 . Continued counter clockwise rotation after the ballast rod 69 has reached its lowest point will again cause the shade material to be wound around the roller and the bar to be lifted.
The depth of the interior space 55 of the bar 7 is preferably at least twice the height of a stripe 31 , 33 , 35 , 37 of the shade material 5 . This ensures that there is enough space for the rear layer 29 to move relative to the front layer 27 between the closed position of the shade 1 when the opaque stripes 31 , 35 of one layer are aligned with the translucent stripes 33 , 37 of the opposite layer and the open position of the shade when the opaque stripes of both layers are aligned.
FIGS. 3A-3D show the assembly of the top portion 39 , 41 of either the front or rear layer 27 , 29 of a woven shade material 5 to the front or rear, top attachment member 23 , 25 and then to the front or rear top groove 15 , 17 of the roller 3 . The assembly will be explained using the front layer 27 and the front top attachment member 23 as an example, but it is identical for the rear layer 29 . In FIG. 3A the front layer 27 and front top attachment member are ready to be assembled, in FIG. 3B they are in a first stage of assembly, in FIG. 3C they are completely assembled and ready for insertion into the front to groove 15 , and in FIG. 3D the front top attachment member 23 with the front layer 27 are in the front top groove 15 .
As shown in FIG. 3A , it is preferred that the top-most translucent stripe 33 A in the top portion 39 of the front layer 27 is an open-structured stripe 71 which includes top and bottom, continuous, longitudinally-extending border lines 73 , 75 along neighboring top and bottom opaque stripes 31 A, 31 B with the border lines being perpendicular to open slots in the open structured stripe 71 . The top attachment member 23 has a left end 77 , a right end 79 and main body 81 in between. The main body 81 includes a plurality of alternating generally outwardly- or upwardly-extending peaks or protuberances 83 and generally inwardly- or downwardly-extending valleys or depressions 85 along its length. When the open-structured stripe 71 of the front layer 27 is lowered onto the top attachment member 23 , the peaks 83 extend through the open-structure of the stripe 71 and outwardly of the front layer. This is shown in FIG. 3B . The front layer is then folded around the top attachment member to keep the peaks 83 extending through, and outwardly away, from the front layer. This is shown in FIG. 3C . Thereby, the attachment member 23 can move within the slot of the open structured stripe 71 and abut against the top border line 73 of the open-structured stripe 71 , adjacent to the top opaque stripe 31 A. Since the top attachment member 23 abuts against the top opaque stripe 31 A, there is an automatic horizontal alignment of the front layer 27 . If necessary, the top border line 73 can be pulled into abutment with the top attachment member after the front layer 27 , with front top attachment member 23 is inserted into the front groove 15 of the roller 3 as shown in FIG. 3D . Once the shade 1 is completely assembled and ballast rod 69 is inserted in hammock-like loop 67 of the rear layer 29 as shown in FIG. 2 , the weight of the ballast rod will ensure alignment of the front and rear layers.
FIG. 4A-4C show the attachment of the front and rear layers 27 , 29 of the shade material 5 to the bottom attachment member 65 . The bottom attachment member 65 is preferably identical to the front and rear top attachment members 23 , 25 . Preferably, the bottom-most translucent stripes 33 B, 37 B of the bottom sections 61 , 63 of the front and rear layers 27 and 29 are open-structured stripes 71 ″ and 71 ′″, respectively. As described above, each open structured stripe 71 ″, 71 ′″ includes top and bottom, continuous, longitudinally-extending border lines 73 ″, 75 ″ and 73 ′″, 75 ′″ along neighboring top and bottom opaque stripes 31 C, 31 D and 35 C, 35 D of the front and rear layers. The bottom attachment member 65 has a left end 77 ″, a right end 79 ″ and a main body 81 ″. The main body 81 ″ includes a plurality of alternating generally upwardly-extending peaks 83 ″ and downwardly-extending valleys 85 ″ along its length. Preferably, the bottom open-structured stripes 71 ″, 71 ′″ of the front and rear layers 27 , 29 are aligned one on top of the other when they are lowered onto the bottom attachment member 65 . The peaks 83 ″ of the bottom attachment member 65 will then extend through the open-structured stripes 71 ″, 71 ′″ of both layers. This is shown in FIG. 4B . The two layers can then be folded around the bottom attachment member 65 to keep the peaks 83 ″ of the bottom attachment member extending outwardly of the layers and extending away from the front layer 27 as shown in FIG. 4C . The attachment member then abuts against the bottom closed border lines 75 ″, 75 ′″ of the open structured stripes 71 ″ and 71 ′″.
The attachment members 23 , 25 , 65 are preferably in the shape of helically wound wires, such as helical springs (e.g., steel springs). Such helical windings can provide the needed peaks and valleys to the attachment members. However, other forms of attachment member can be used, so long as they have a plurality of alternating peaks and valleys along the length of the attachment member.
FIG. 5 shows five alternative embodiments 123 , 223 , 323 , 423 , 523 of attachment members which are similar to the attachment member 23 of FIGS. 3 and 4 and for which corresponding reference numerals (greater by 100, 200 or 300) are used below for describing the same parts or corresponding parts.
In FIG. 5A , an attachment member 123 is an elongated rod-like structure 181 , along the axis of which, wheel-like portions or peaks 183 of greater radius alternate with wheel-like portions or valleys 185 of smaller radius. In FIGS. 5B and 5C , comb-like attachment members 223 , 323 each have an elongated body 281 , 381 with teeth or peaks 283 , 383 alternating with openings or valleys 285 , 385 . In FIGS. 5D and 5E , comb-like attachment members 423 , 523 each have an elongated body 481 , 581 with a pair of teeth or peaks 483 , 583 alternating with openings or valleys 485 , 585 . In FIG. 5D , each peak 483 is a substantially round disk, and in FIG. 5E , each peak 583 is wedge-shaped.
The top and bottom open-structured stripes 71 , 71 ″ and 71 ′″ of the front and rear layers 27 , 29 of the sheet material 5 can be any type of open-structured material. It is preferred that each stripe 71 , 71 ″ and 71 ′″ includes a plurality of vertically-extending bridging members 87 between its top and bottom border lines 73 , 73 ″, 73 ′″, 75 , 75 ″, 75 ′″. These bridging members 87 are preferably distributed along the longitudinal length of each open-structured stripe. The bridging members can be formed by cutting away material from the front and rear layers 27 , 29 in their top-most and bottom-most translucent stripes. When the front and rear layers are assembled with the attachment members 23 , 25 , 65 , 123 , 223 , 323 , 423 , 523 each peak 83 , 183 , 283 , 383 , 483 , 583 of an attachment member extends through an open-structured stripe 71 , 71 ″, 71 ′″ between, and outwardly of, a pair of adjacent bridging members 87 of the layers. Preferably, the double-layer fabric shade material 5 is woven with its open-structured stripes being formed by omitting warp or weft threads of the fabric, thereby forming the bridging members 87 as weft or warp threads.
It is not necessary that the number of peaks 83 , 183 , 283 , 383 , 483 , 583 on the attachment members 23 , 25 , 65 , 123 , 223 , 383 , 483 , 583 and the number of bridging members 87 in the open-structured stripes 71 , 71 ″ and 71 ′″ are equal. For a minimal alignment of the shade material 5 with the roller 3 , only about two peaks on each attachment member are needed. See FIGS. 5D and 5E . The longitudinal spacing between adjacent bridging members 87 is not considered critical, so long as at least two peaks extend between adjacent pairs of bridging members.
FIG. 6 shows an alternative embodiment of a layer 627 of a two-layer shade material 605 of the invention which is similar to the front layer 27 of the shade material 5 FIGS. 3 and 4 and for which corresponding reference numerals (greater by 600 ) are used below for describing the same parts or corresponding parts.
Shown in FIGS. 6A-6C , the layer 627 of the two-layer shade material 605 is a non-woven material. Which can be a non-woven fabric but can also be a plastic sheet material or the like. A plurality of longitudinally-adjacent open-structured stripes 671 are cut into the top-most translucent stripe 633 A in the top portion 639 of the layer 627 and bridging members 687 are left between the open-structured stripes 671 . Each open-structured stripe 671 includes top and bottom, closed longitudinally-extending border lines 673 , 675 along neighboring top and bottom opaque stripes 631 A, 631 B. FIG. 6A shows the layer 627 and a front attachment member 423 of FIG. 5D prior to being assembled. FIG. 6B shows the layer 627 positioned over the front attachment member 423 with its peaks 483 directly underneath the open-structured stripes 671 of the layer. FIG. 6C shows the peaks 483 of the front attachment member 423 inserted into the open-structured stripes 671 of the layer 627 , between its bridging members 687 and the layer then folded around the attachment member, with the peaks 483 outside of, and extending away from the layer, so that the attachment member can then be inserted into the front groove 15 of the roller 3 of the shade 1 .
In FIG. 6 , the bridging member 687 are shown as relatively wide, and the spacings between them are relatively narrow. However, this is not necessary. Likewise, the attachment member 423 is shown with two peaks 483 , but it could have more peaks.
This invention is, of course, not limited to the above-described embodiments which may be modified without departing from the scope of the invention or sacrificing all of its advantages. In this regard, the terms in the foregoing description and the following claims, such as “longitudinal”, “vertical”, “horizontal”, “top”, “bottom”, “radial”, “clockwise”, “counter-clockwise”, “right” and “left”, have been used only as relative terms to describe the relationships of the various elements of this invention for architectural coverings.
For example, the layers of the shade material 5 of the roller shade 1 can be fabric, preferably a woven or knit fabric (as shown in FIGS. 3 and 4 ), or a non-woven fabric or perforated plastic sheet (as shown in FIG. 6 ). However, with a non-woven fabric, separate border lines 673 , 675 are preferably provided, for example by providing a line of adhesive or an adhesively attached reinforcing strip along the top and bottom borders of the open-structured stripes 671 .
Moreover, the roller 3 can be at the bottom of the shade 1 and the bar 7 can be at the top of the shade. | A system for attaching a shade material to a roller having recesses in its surface includes inserting portions of the shade material into an associated elongated recess and retaining the material in the recess with an attachment member having peaks and valleys along its length for intermittent engagement with the material within the recess. | 4 |
FIELD OF THE INVENTION
This invention relates generally to the storage of watercraft and, more particularly, to a personal watercraft support structure that is modular in configuration and maintains the watercraft in close proximity to the water despite tidal changes or watercraft weight.
BACKGROUND OF THE INVENTION
Boating is a popular outdoor activity that is shared among friends and family members. The unpredictability of water lends a challenge to the boater and, depending on the size of the boat, typically requires at least two individuals to operate a boat safely. However, the introduction of personal watercraft has made operation by a single individual possible. This ability has made boating an affordable activity which may now be enjoyed by all individuals.
Personal watercraft includes jet-skis, wave runners, and similar water going vessels. Such watercraft can be easily maneuvered by a single individual. These watercraft are typically propelled by a water jet formed integral to the vessel. An individual need only operate simple controls to cause operation of the vessel to propel an individual to high speeds.
Although personal watercraft may be transported on a trailer, many individuals choose to leave such vessels in the water. However, unless properly conditioned, extended storage in the water can result in damage to the watercraft. For instance, the outer surfaces of a wave runner that is kept in a fresh water lake may become fouled with algae. This fouling will diminish vessel performance and detract from appearance of the watercraft. In addition, the algae may foul the propulsion jet. Additionally, if the vessel's engine is water cooled, algae buildup may foul the cooling system leading to premature engine failure. This fouling problem is even more troublesome if foreign matter such as mussel zebras attach to the operating components.
In addition, should a watercraft develop a leak in the hull, there is a possibility that the watercraft may sink if left unattended. Even visual inspection does not always reveal hull damage. For example, hydrolysis of the fiberglass can result in a hull breach that may result in a slow sinking of the vessel.
Leaving a watercraft in salt water can also be troublesome. Salt water, especially warm tropical water, can quickly cause vessel fouling. Barnacles will attach to the hull of a vessel and, in light of their hard shell, cause a most noticeable reduction in watercraft efficiency. Should the barnacles attach themselves to the cooling or jet intake, the result will be engine damage.
For these reasons, watercraft is raised out of the water to prevent the onslaught of problems, while keeping the vessel close to the water for ease of use. Large flotation platforms allow an individual to place a watercraft on top of the structure to inhibit contact with water. Some floating structures allow the watercraft to drive onto the support. However, if the structure is rigid, the watercraft may be damaged during the maneuver.
Another problem with floating structures of the prior art is that most such structures are fixed in length making them difficult to transfer or store. In the northern half of the United States, watercraft must be removed for the winter season due to the icing conditions. In these circumstances, the support structure must be removed. Due to structure size and associated weight, most structures are removed by several individuals. In addition, once the structure is removed, the size may cause difficulty in storing or transporting to another location.
Another problem with the prior art floating structures is the design parameters which require the structure to be sized to accommodate a type or size of watercraft. Watercraft may hold one, two, or more individuals. If the floating support structure is inappropriately sized or inadequate for a given vessel, a vessel owner may have to exchange the entire structure. In addition, should the vessel owner choose to purchase a larger watercraft, or a small boat, a fixed-sized support structure will not be adequate.
Thus, what is lacking in the art is a watercraft support structure that is lightweight in construction, modular in design, and allows for ease of assembly, disassembly, and storage. Additionally, there is a need for a modular watercraft support that will accommodate vessels of various lengths and may be increased in size to support small boats.
Watercraft of various types are referred to throughout this application. While specific examples of watercraft are given for illustrative purposes, it is to be understood that the present invention is suitable for all types of vessels which travel on water. These vessels include, but are not limited to small fishing boats, inflatable boats, kayaks, inflatable boats, rowing skulls, jet-propulsion boats, outboard and inboard/outboard boats, and seaplanes.
SUMMARY OF THE INVENTION
The instant invention is a floating storage device for personal watercraft. The device employs a group of rigid platforms that are joined together by the use of linking arms and interlocking pins. The linking arms extend from each platform and are interlocked in such a manner so as to allow for flexibility in support, which assists in vessel loading. The linking pins pass through bores in the overlapped linking arms to secure the platforms in a contiguous linear series. The pins are removable and allow the structure to be modified to a particular structure length. The device is tethered to a dock by tethering posts that pass vertically through selected bores not otherwise occupied by linking pins.
Each platform within the device is shaped according to its intended use. A flat platform is designed to allow walking and standing by individuals, a cradling platform is designed to support the hull of a watercraft, and a ramp section is shaped to support a portion of the hull of a watercraft and to allow entry of the watercraft onto the device. Additionally, each platform is filled with foam to increase the rigidity and buoyancy of each platform.
The modular shape allows a combination of any platform thereby permitting the structure to be expanded by simply adding additional platforms. In this manner the structure may support a single person wave runner or be expanded to accommodate a 40 foot lightweight boat such as the Scraabb.
The platforms are formed from a mixture of polyethylene and an emulsifier that is placed in a rotating mold. The heating of the mixture results in a hard shell with seceding layers of density through the platform. The result is a rigid platform that cannot sink despite breaching in the structure or withhold water within the structure.
Accordingly, it is an object of the present invention to provide a watercraft support structure which lifts a watercraft hull above the waterline.
Still another object of the present invention is to provide a watercraft support structure which is modular in design to allow several platforms to be linked together.
A further object of the present invention is to provide a watercraft support structure having sloped, overlapping pieces that allow hinge-type pivoting of adjacent platforms.
Yet still a further object of the present invention is to provide a watercraft support structure which is a shell filled with a buoyant material that bonds with the inside walls of the shell to give structural support to the shell, while providing device buoyancy.
Still yet another object of the present invention is to provide a watercraft support device which provides dynamic support of a vessel during loading and unloading.
Other objects and advantages of this invention will become apparent from the following description taken in conjunction with the accompanying drawings wherein are set forth, by way of illustration and example, certain embodiments of this invention. The drawings constitute a part of this specification and include exemplary embodiments of the present invention and illustrate various objects and features thereof.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a pictorial view showing the present invention secured to a dock;
FIG. 2 is a spaced-apart, perspective view of the present invention;
FIG. 3 is a side elevation view of a flat platform of the present invention;
FIG. 4 is a back elevation view of a flat platform of the present invention;
FIG. 5 is a side elevation view of an intermediate platform of the present invention;
FIG. 6 is a back elevation view of an intermediate platform of the present invention;
FIG. 7 is a side elevation view of a ramp platform of the present invention;
FIG. 8 is a back elevation view of a ramp platform of the present invention;
FIG. 9 is a perspective view of a linking pin of the present invention;
FIG. 10 is a perspective view of an expanded version of the present invention;
FIG. 11 is a perspective view of a single-piece embodiment of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
Although the invention is described in terms of a specific embodiment, it will be readily apparent to those skilled in this art that various modifications, rearrangements and substitutions can be made without departing from the spirit of the invention. The scope of the invention is defined by the claims appended hereto.
Reference is made in general to the Figures, wherein a watercraft support device 10 is shown, and depicted specifically in FIG. 1. The device 10 comprises a flat platform 12, a cradling platform 14, and a ramp platform 16. The platforms Aeneid 16 are linked together and provide a floating surface on which a watercraft may be parked. As will be described below, the device 10 is attached to a dock 18 via tethering posts 19 which are permanently secured to the dock 18 and which pass through vertical bores 20,20' in the device.
Now referring generally to FIGS. 2-4, the flat platform 12 is a substantially-rectangular, rigid structure having a horizontal upper surface 22 spaced apart from a horizontal lower surface 24 by a first vertical sidewall 26, a second vertical sidewall 28, a vertical front wall 30, and a vertical back wall 32. An integral frontal linking arm 34 extends from the front wall 30. The frontal linking arm 34 is bounded by the upper surface 22, first sidewall 26, and second sidewall 28 of the flat platform 12. The frontal linking arm 34 has an inclined bottom surface 36. As such, the distance between the upper surface 22 and the bottom surface 36 decreases from a maximum near the flat platform front wall 30 to a minimum at a distal end 38 of the linking arm 34. An integral rearward linking arm 40 extends from the back wall 32. The rearward linking arm 40 is bounded by the lower surface 24, first sidewall 26, and second sidewall 28 of the flat platform 12. The rearward linking arm 40 has an inclined top surface 42. As such, the distance between the lower surface 24 and the top surface 42 decreases from a maximum near the flat platform back wall 32 to a minimum at a distal end 44 of the linking arm 40.
Now referring generally to FIGS. 2, 5, and 6, the cradling platform 14 is a substantially-rectangular, rigid structure having a horizontal upper surface 46 spaced apart from a horizontal lower surface 48 by a first vertical sidewall 50, a second vertical sidewall 52, a vertical front wall 54, and a vertical back wall 56. An integral frontal linking arm 58 extends from the front wall 54. The frontal linking arm 58 is bounded by the upper surface 46, first sidewall 50, and second sidewall 52 of the cradling platform 12. The frontal linking arm 58 has an inclined bottom surface 60. As such, the distance between the upper surface 46 and the bottom surface 60 decreases from a maximum near the cradling platform front wall 54 to a minimum at a distal end 62 of the linking arm 58. An integral rearward linking arm 64 extends from the back wall 56. The rearward linking arm 64 is bounded by the lower surface 48, first sidewall 50, and second sidewall 52 of the cradling platform 12. The rearward linking arm 64 has an inclined top surface 66. As such, the distance between the lower surface 48 and the top surface 66 decreases from a maximum near the cradling platform back wall 56 to a minimum at a distal end 68 of the linking arm 64. An arched support channel 70 rises upward from the cradling platform upper surface 46. The support channel 70 runs the longitudinal length of the upper surface 46. The support channel 70 resembles a half-pipe which opens upward. To ease loading and unloading of a watercraft, the channel 70 advantageously has a smooth surface to keep sliding friction between the channel 70 and the watercraft to a minimum.
Now referring generally to FIGS. 2, 7, and 8, the ramp platform 16 is a substantially-rectangular, rigid structure having a horizontal upper surface 72 spaced apart from a horizontal lower surface 74 by a first vertical sidewall 76, a second vertical sidewall 78, a vertical front wall 80, and a vertical back wall 82. An integral frontal linking arm 84 extends from the front wall 80. The frontal linking arm 84 is bounded by the upper surface 72, first sidewall 76, and second sidewall 78 of the cradling platform 14. The frontal linking arm 84 has an inclined bottom surface 86. As such, the distance between the upper surface 72 and the bottom surface 86 decreases from a maximum near the ramp platform front wall 80 to a minimum at a distal end 88 of the linking arm 84. An integral rearward linking arm 90 extends from the back wall 82. The rearward linking arm 90 is bounded by the upper surface 72, first sidewall 76, and second sidewall 78 of the ramp platform 12. The rearward linking arm 90 has a horizontal bottom surface 92. An arched support channel 94 extends upward from the ramp platform upper surface 72. The support channel 94 resembles a half-pipe which opens upward. To ease loading and unloading of a watercraft, the channel 94 advantageously has a smooth surface to keep sliding friction between the channel 94 and the watercraft to a minimum. The support channel 94 runs the longitudinal length of the ramp platform upper surface 72. Near the ramp platform back wall, however, the support channel is tapered, passing through the rearward linking arm 90 to form a ramped entrance 98. The ramped entrance 98 resembles a three-sided funnel. The entrance 98 serves to guide a watercraft into the support channels 70,94. The entrance 98 also provides an incline along which a watercraft may travel during loading, as it leaves the water, or during unloading, as it enters the water. As a result, the ramped entrance 98 advantageously eliminates the need for a lifting crane to raise or lower the watercraft.
Referring to FIGS. 3 and 4, frusto-conical bores 20,20' extend vertically through flat platform frontal linking arm 34. Bore 20 passes through linking arm 34 near the first sidewall 26, while bore 20' passes through linking arm 34 near the second sidewall 28. The bores 20,20' are tapered: their diameters decrease from a maximum near the upper surface 22 to a minimum near the linking arm bottom surface 36. Frusto-conical bores 100,100' extend vertically through flat platform rearward linking arm 40. Bore 100 passes through linking arm 40 near the first sidewall 26, while bore 100' passes through linking arm 40 near the second sidewall 28. The bores 100,100' are tapered: their diameters decrease from a maximum near the lower surface 24 to a minimum near the linking arm top surface 42. Each bore 20,20',100,100' is characterized by a pair of vertical channels 110. The bores 20,20',100,100' and channels 110 are shaped to accept linking pins 112 and their associated locking tabs 114.
Referring to FIGS. 5 and 6, frusto-conical bores 102,102' extend vertically through cradling platform frontal linking arm 58. Bore 102 passes through linking arm 58 near the first sidewall 50, while bore 102' passes through linking arm 58 near the second sidewall 52. The bores 102,102' are tapered: their diameters decrease from a maximum near the upper surface 46 to a minimum near the linking arm bottom surface 60. Frusto-conical bores 104,104' extend vertically through cradling platform rearward linking arm 64. Bore 104 passes through linking arm 64 near the first sidewall 50, while bore 104' passes through linking arm 64 near the second sidewall 52. The bores 104,104' are tapered: their diameters decrease from a maximum near the lower surface 48 to a minimum near the linking arm top surface 66. Each bore 102,102',104,104' is characterized by a pair of vertical channels 110. The bores 102,102',104,104' and channels 110 are shaped to accept linking pins 112 and their associated locking tabs 114.
Referring to FIGS. 7 and 8, frusto-conical bores 106,106' extend vertically through ramp platform frontal linking arm 84. Bore 106 passes through linking arm 84 near the first sidewall 76, while bore 106' passes through linking arm 84 near the second sidewall 78. The bores 106,106' are tapered: their diameters decrease from a maximum near the upper surface 72 to a minimum near the linking arm bottom surface 86. Frusto-conical bores 108,108' extend vertically through ramp platform rearward linking arm 90. Bore 108 passes through linking arm 90 near the first sidewall 76, while bore 108' passes through linking arm 90 near the second sidewall 78. The bores 108,108' are tapered: their diameters decrease from a maximum near the upper surface 72 to a minimum near the arm bottom surface 92. Each bore 106,106',108,108' is characterized by a pair of vertical channels 110. The bores 106,106',108,108' and channels 110 are shaped to accept linking pins 112 and their associated locking tabs 114.
Referring generally to FIGS. 2 and 9, linking pins 112 are used to secure adjacent platforms 12,14,16 together. Each pin 112 has an enlarged head plate 116 and a cylindrical body 118. A pair of locking tabs 114 extends radially from the body 118, near the bottom of the pin 112. The tabs 114 are sized to fit bore channels 110. A example of pin 112 use is now provided. The back wall 32 of flat platform 12 is placed against front wall 54 of cradling platform 14, so that the flat plate rearward linking arm 40 overlaps cradling platform frontal linking arm 58, and bores 100,100' are aligned with bores 102,102'. A linking pin 112 is positioned over bore 102. The pin 112 is pushed down and fed through bore 102 into bore 100. When the locking tabs 114 emerge past the lower surface 24 of the flat platform frontal linking arm 40, the pin 112 is rotated until the tabs 114 are no longer aligned with the channels 110 of bore 100, thus securing the pin 112 within the bores 100,102. This procedure is repeated with aligned bores 102' and 100'. The ramp platform frontal linking arm 84 is attached to the cradling platform rearward linking arm 64 in a similar fashion. Additional platforms may be added by repeating this overlapping and linking pin 112 placement procedure with as many platforms 12,14,16 as are needed.
In one embodiment, the device is secured to a dock 18 via tethering posts 19 which pass through selected bores 20,20'. The posts 19 are part of a four-piece unit. The unit includes a pipe securing ring 120 which is bolted to a vertical face of the dock 18. A horizontal piece of pipe 122 extends away from the dock 18, outward from the ring 120. A ninety-degree transition elbow 124 is glued to the free end of the horizontal pipe 122. A vertical piece of pipe 19 extends from the elbow 124, downward into the water. The vertical pipe 19 extends into the water far enough so that the bottom edge of the pipe 19 is below the water surface at all times, even during possible low tides. The outer diameter of the vertical pipe 19 is chosen to allow unencumbered vertical motion of the device 10, in response to tides or wave action. In one embodiment, the vertical pipes 19 have an outer diameter of six inches, while the bores 20,20' have a minimum inner diameter of seven inches. Although the tethering posts 19 have been described as part of a four-piece unit, other configurations may be used. For example, a piling driven into an underwater surface may also be sufficient.
A watercraft is loaded onto the support device 10 by driving the watercraft towards the device 10 and aiming the bow of the watercraft towards the ramped entrance 98. As the watercraft enters the ramped entrance 98, the watercraft's bow will travel upward and enter the ramp platform support channel 94. As the watercraft travels along the ramped entrance 98, the ramp platform 16 will tend to tilt. That is, the back wall 82 will move down, and the front wall 80 will move up. This tilting is controlled by the linking pins 112 which are locked into place within bores 104,104',106,106'. Since the bores 104,104',106,106' are frusto-conical and the pins 112 are cylindrical, the ramp platform frontal linking arm 84 and the cradling platform rearward linking arm 64 are attached, essentially, in a hinge-like fashion. Additionally, the incline found on the bottom surface 86 of the ramp platform frontal linking arm 84 is opposite the incline found on the top surface 66 of the cradling platform rearward linking arm 64. These opposite inclines allow the ramp platform frontal linking arm 84 to pivot away from cradling platform rearward linking arm 64 without damage to either arm.
As more of the watercraft travels further onto the device 10, the cradling platform 14 begins to tilt with respect to the flat platform 12. This titling is facilitated by the cooperation of bores 100,100',102,102' and the linking pins 112 secured therein. As described above, the frusto-conical shape of the bores 100,100',102,102' combines with the cylindrical shape of the pins 112 to provide a hinge-like linkage between the flat platform 12 and the cradling platform 14. Additionally, the incline found on the bottom surface 60 of the cradling platform frontal linking arm 58 is opposite the incline found on the top surface 42 of the flat platform rearward linking arm 40. These opposite inclines allow the cradling platform frontal linking arm 58 to pivot away from flat platform rearward linking arm 40 without damage to either arm.
When the watercraft is completely loaded onto the device 10, the support channels 70,94 will keep the watercraft upright, allowing individuals to enter or leave the watercraft. The weight of the watercraft and individuals is supported by the device 10. The watercraft 10 may be unloaded by reversing the above-described procedure.
Although the device 10 has been described as containing one flat platform 12, one cradling platform 14, and one ramp platform 16, other configurations may be used. As shown in FIG. 10, several of each type of platform 12,14,16 may be used to accommodate an individual's docking needs or watercraft size. A one-piece embodiment, as shown in FIG. 11, is also possible.
In addition, although the device 10 has been shown with its longitudinal axis oriented perpendicular to the longitudinal axis of a dock 18, other orientations are possible. For example, the device 10 may be rotated ninety degrees so that the longitudinal axis of the device 10 is parallel to the longitudinal axis of the dock 18. In such a case, the distance between tethering posts 19 is increased and the posts 19 would pass through bores 20',108' of several platforms 12,16. The linking pins 112 and tethering posts are sized to fit within each of the platform bores 20,20',100,100',102,102',104,104',106,106',108,108'.
The watercraft support is manufactured by use of a clamshell mold having an internal cavity in the shape of one of the platforms. A predetermined mixture of polyethylene and an emulsifier is injected into the clamshell mold and the mold is then heated to a first temperature for about an hour. During the heating process, the clamshell is rotated while heating the mold causing the mixture to coat the internal cavity. The clamshell mold is then heated to a second predetermined raised temperature for a second predetermined period of time, causing the emulsifier to produce gas bubbles. Rotating of the clamshell mold continues until the mixture is allowed to cool.
It is to be understood that while I have illustrated and described certain forms of my invention, it is not to be limited to the specific forms or arrangement of parts herein described and shown. It will be apparent to those skilled in the art that various changes may be made without departing from the scope of the invention and the invention is not to be considered limited to what is shown in the drawings and described in the specification. | A watercraft support structure formed from a plurality of rigid platforms that are coupled together by the use of linking pins. Each platform having independent buoyancy formed integral therein for support of most any size watercraft. The structure includes multiple ramp, cradle, and flat platforms, allowing an individual to customize a support structure for a particular sized watercraft. The platforms allow the structure to raise or fall with each tidal change and include a hinge-type connection that promotes ease of loading and unloading of a watercraft. | 1 |
BACKGROUND OF THE INVENTION
This invention relates to an apparatus for assisting in maintenance of rail roadbeds. More specifically, it relates to an apparatus for guiding new ties into the roadbed and for holding tie plates against rails when ties are being replaced.
In order to maintain railroad tracks in safe operating condition, it is necessary to replace the ties periodically. The ties (made of wood, metal or concrete) underneath the rails tend to wear out after an extended period of use. Various machines have been developed for removing and/or inserting the ties.
Among problems encountered in use of such machines are the handling of the tie plates when old ties are removed. Manual handling of the tie plates slows down the process and increases costs and safety risks. Absent intervention, the tie plates simply drop to the roadbed when the old ties are removed.
Another problem is getting a new tie to slide into the cavity left by removal of the old tie without catching on the rails (which rails are lifted during removal and insertion), any tie plates held against the rails, and other obstructions.
The following U.S. patents, assigned to the assignee of the present application and hereby incorporated by reference, show various such machines:
______________________________________U.S. Pat. No. Inventor Issue Date______________________________________4,951,573 Madison August 28, 19905,048,424 Madison et al September 17, 19915,197,389 Glomski et al March 30, 1993______________________________________
Madison '573 discloses a tie remover/inserter using the structure of a modified backhoe.
Madison and Newman '424 discloses a tie replacer including a tie guide structure to help guide the new tie into proper position without catching on obstructions. It uses electromagnets to hold tie plates against the uplifted rails.
Glomski, Newman, and Madison '389 discloses a tie replacer with a tie guide assembly and air-cylinder operated magnets to hold the tie plates against the rails.
U.S. Pat. No. 4,241,663 issued Dec. 30, 1980 to Lund et al. discloses use of electromagnets to hold tie plates to rails.
Although those and various other devices for tie plate handling and/or tie guiding have been generally useful, they have been subject to one or more disadvantages.
Those devices using magnets or electromagnets for holding tie plates often pick up metal parts (such as loose tie plate spikes) other than tie plates. Such other metal parts may prevent the devices from securely holding the tie plates against the rails. Further, even non-metallic debris, such as ballast, may get between the tie plates and the magnets or electromagnets and cause tie plates to drop free of the rails.
The guide assemblies or structures for guiding ties into place often still have problems with debris blocking ties as they go into place. Further, it often requires great force to overcome friction and to get the ties into place using such tie guides. Finally, such tie guides often allow or cause wandering of the tie as it is inserted. In other words, the tie doesn't maintain its orientation perpendicular to the rails during insertion.
OBJECTS AND SUMMARY OF THE INVENTION
Accordingly, it is a primary object of the present invention to provide a new and improved tie guide and tie plate holding assembly.
A more specific object of the present invention is to provide a tie guide which eases insertion of ties and reduces the amount of force required to insert a new tie.
A further object of the present invention is to provide a tie plate holder which avoids or minimizes problems from debris.
Yet another object of the present invention is to provide a tie plate holder and tie guide which are highly efficient and reliable.
The above and other features of the present invention which will be more readily understood when the following detailed description is considered in conjunction with the accompanying drawings are realized by an apparatus for aiding in tie replacement operations including: a frame; and first and second side clamp assemblies supported by the frame. Each of the first and second clamp assemblies have a pair of opposing field side mechanical grip elements and a pair of opposing gauge side mechanical grip elements, the pairs of field side and gauge side mechanical grip elements operable to grip tie plates when ties thereunder are removed and replaced. The pairs of field side and gauge side mechanical grip elements are self-centering such that when gripping a tie plate each pair of mechanical grip elements will automatically center about the tie plate prior to gripping the tie plate and without moving the tie plate. The first and second clamp assemblies further include respective corresponding first and second grip hydraulic cylinders. Each pair of mechanical grip elements are attached for movement with opposing rod and cylinder ends of one of the first and second hydraulic cylinders.
Each of the first and second clamp assemblies further include at least one spring corresponding to each hydraulic cylinder and operably connected to the corresponding mechanical grips for self-centering thereof. More preferably, each of the first and second clamp assemblies further includes two springs corresponding to each hydraulic cylinder and operably connected to the corresponding mechanical grips for self-centering thereof.
The frame is an apparatus frame with at least a first frame lifter connected to the apparatus frame for moving the apparatus frame between upper and lower frame positions relative to a vehicle main frame. There are first and second clamp assembly lifters for vertically moving the respective first and second clamp assembly lifters relative to the apparatus frame.
The apparatus further includes a tie guide supported by the frame, the tie guide having a plurality of rollers on an underside thereof, the rollers operable to minimize friction between the tie guide and a new tie being inserted under the tie guide. A first sweeper supported by the apparatus frame and positioned to sweep debris off the top of ties being inserted.
The apparatus is combined with a tie replacer vehicle.
The present invention may alternately be described as an apparatus for aiding in tie replacement operations including: a apparatus frame with at least a first frame lifter connected to the apparatus frame for moving the apparatus frame between upper and lower frame positions relative to a vehicle main frame; and a first side clamp assembly supported by the apparatus frame and having mechanical grip elements operable to grip tie plates when ties thereunder (i.e., under the first side clamp assembly) are removed and replaced. The first side clamp assembly includes a pair of opposing field side mechanical grip elements and a pair of opposing gauge side mechanical grip elements, the pairs of field side and gauge side mechanical grip elements operable to grip tie plates when ties thereunder are removed and replaced.
The apparatus further includes a second side clamp assembly supported by the apparatus frame and having mechanical grip elements operable to grip tie plates when ties thereunder are removed and replaced, and wherein the second side clamp assembly includes a pair of opposing field side mechanical grip elements and a pair of opposing gauge side mechanical grip elements, the pairs of field side and gauge side mechanical grip elements operable to grip tie plates when ties thereunder are removed and replaced. The mechanical grip elements include a pair of self-centering mechanical grip elements such that when gripping a tie plate the pair of mechanical grip elements will automatically center about the tie plate prior to gripping the tie plate and without moving the tie plate. The first side clamp assembly further includes at least one spring operably connected to self-center the pair of mechanical grip elements. More specifically, the mechanical grip elements are pairs of self-centering field side and gauge side mechanical grip elements such that when gripping a tie plate each pair of mechanical grip elements will automatically center about the tie plate prior to gripping the tie plate and without moving the tie plate.
A second side clamp assembly is supported by the apparatus frame on a side opposite the first side clamp assembly and has mechanical grip elements operable to grip tie plates when ties thereunder are removed and replaced.
A tie guide is supported by the apparatus frame, the tie guide having a plurality of rollers on an underside thereof, the rollers operable to minimize friction between the tie guide and a new tie being inserted under the tie guide. A first sweeper is supported by the apparatus frame and positioned to sweep debris off the top of ties being inserted.
The present invention may alternately be described as an apparatus for aiding in tie replacement operations including: an apparatus frame with at least a first frame lifter connected to the apparatus frame for moving the apparatus frame between upper and lower frame positions relative to a vehicle main frame; and a tie guide supported by the apparatus frame, the tie guide having a plurality of rollers on an underside thereof, the rollers operable to minimize friction between the tie guide and a new tie being inserted under the tie guide. A tie guide lifter operably connects the tie guide to the apparatus frame for causing relative vertical movement therebetween. A first side clamp assembly supported by the apparatus frame and having mechanical grip elements operable to grip tie plates when ties thereunder are removed and replaced.
The present invention may alternately be described as an apparatus for aiding in tie replacement operations including: an apparatus frame with at least a first frame lifter connected to the apparatus frame for moving the apparatus frame between upper and lower frame positions relative to a vehicle main frame; a tie guide supported by the apparatus frame; a first side tie plate holder supported by the apparatus frame and operable to grip tie plates when ties thereunder are removed and replaced; and a first sweeper supported by the apparatus frame and positioned to sweep debris off the top of ties being inserted. A second sweeper is supported by the apparatus frame and positioned to sweep debris off the top of ties being inserted. A tie guide lifter operably connects the tie guide to the apparatus frame for causing relative vertical movement therebetween. The tie plate holder includes a first side clamp assembly supported by the apparatus frame and having mechanical grip elements operable to grip tie plates when ties thereunder are removed and replaced.
BRIEF DESCRIPTION OF THE DRAWINGS
The above and other features of the present invention will be more readily understood when the following detailed description is considered in conjunction with the accompanying drawings wherein like characters represent like parts throughout the several views and in which:
FIG. 1 shows a schematic side view of a vehicle according to the present invention;
FIG. 2 shows a perspective view of an apparatus for aiding in tie replacement operations according to the present invention;
FIG. 3 shows an end view of the apparatus of FIG. 2;
FIG. 4 shows a perspective view, with some parts removed for ease of illustration, of a portion of the apparatus;
FIG. 5 is a side view of portions of the apparatus;
FIG. 6 is a top view of a tie and a portion of a sweeper of the apparatus; and
FIG. 7 is a simplified cross sectional view along lines 7--7 of FIG. 6.
DETAILED DESCRIPTION
With reference initially to FIG. 1, a tie replacing vehicle 10 has a main frame 10M and front and back pairs of rail engagement wheels 10W (only one of each pair visible). A tie replacer apparatus 12 is depicted schematically, as are rail clamps 14 and a tie guide/plate holding apparatus 16.
The vehicle 10, tie replacer 12, rail clamps 14, and various other (unshown) parts of the vehicle may be constructed in the fashion shown and described in the above mentioned and incorporated by reference U.S. Patents Madison et. al '424 and/or Glomski et. al '389. However, the tie guide/plate holder 16 is constructed differently from arrangements of those patents and will be discussed in detail below.
Turning now to FIGS. 2 and 3, the tie guide/plate holder 16 is an apparatus for assisting in the replacement of ties. This guide/holder apparatus 16 serves to hold tie plates P against rails R when an old tie T is being removed and a new tie (not shown) is being inserted. The vehicle 10 will lift the rails R to allow removal of the old tie T and its replacement by a new tie in the manner discussed in Madison '424 and Glomski '389. In addition to holding the tie plates P against the rails R during the tie removal and insertion process, apparatus 16 will guide a new tie in place without it binding against the rails R or other possible obstacles.
The apparatus 16 includes an apparatus frame 18 attached to main or vehicle frame 10M (FIG. 3 only) by front and back scissor linkages 20. The linkages 20 are controlled by hydraulic cylinders 22 which extend to lift apparatus frame 18 into an upper, inoperative or travel position relative to vehicle frame 10M and retract to extend linkages 20 and lower apparatus frame 18 into a lower, operative or working position relative to vehicle frame 10M. Linkages 20 and cylinders 22 together serve as a frame lifter for vertically moving apparatus frame 18.
When lowered into its illustrated working position, apparatus frame 18 has front and back pair of flanged wheels 24 (not all 4 are visible) in contact with the rails R. The apparatus frame 18 has plates 26 and 28 (momentarily view FIG. 5) which are fixed respectively to members 30 and 32 of frame 18.
As best shown in FIG. 2, frame 18 includes right and left pairs of plates 34 to which links 36 are pivotably attached at axles 36A. Plate clamp assemblies 38 have plates 40 pivotably attached at points 40P to ends of the links 36. Hydraulic actuators or cylinders 42 have rod ends secured to plates 44, which are part of apparatus frame 18. The barrel or cylinder ends of actuators 42 are pivotably attached to plates 46 which in turn are mounted to shafts 48. (As will be apparent, the apparatus 16 is symmetric with respect to its right and left sides corresponding to the rails R.) Right and left actuators 42 extend to lift corresponding right and left assemblies 38 by lifting shafts 48 and plates 40 with pivoting at points 40P and axles 36A. Retracting an actuator 42 would lower the corresponding assembly 38 including plates 40 and other parts discussed below.
When lifted into their upper positions, the assemblies 38 are raised such that the vehicle may be indexed or moved until the assemblies 38 are over a tie to be replaced. Assemblies 38 may then be lowered into an operative position for plate clamping as will be discussed. Links 50 (only one visible, right side of FIG. 2, but there is right field side, right gauge side, left field side, and left gauge side of these links) connect to blocks 52 (only one visible, would be right and left side such blocks). The blocks 52 are fixed to corresponding plates 40 and are part of the assemblies 38. The links 50 maintain the proper orientation for assemblies 38 as they are lifted and lowered, links 50, links 36, plates 18, and portions of assemblies 38 collectively constituting a four bar linkages.
Continuing to view FIG. 2, but also referring to FIG. 4, the details of the plate clamp assembly 38 will be discussed. For ease of illustration, the field one of the plates 40 is removed from FIG. 4. It should be appreciated that, not only is there identical right and left side of the plate holding assemblies or holders 38, but the field and gauge side of holding assemblies 38 are identical.
Above the field block 52 (FIG. 4) is a center plate 54 connecting it to a corresponding, not visible, gauge block, all of which are fixed to plates 40. The center plate 54 has a mount 56 to which shaft 58 is fixed with springs 60 movably capturing mounts 62 at opposite ends thereof. The mounts 62 are trapped by lock nuts or rings (not shown) at ends of shaft 58 such that shaft 58 does not slip out of the holes in mounts 62. Mounts 62 are part of end plates 64 which, like center plate 54, extend between identical field and gauge components. End plates 64 have blocks 66 fixed to them and are retracted/extended by operation of jaw cylinder 67. Blocks 66, captured to slide on shaft 69, in turn have jaws or grip elements 68 secured to them. It will therefore be readily appreciated that the grip elements 68 are attached or mounted for sliding movement in a straight line corresponding to movement along shaft 69, which direction of movement is parallel to an extension/retraction direction for the hydraulic cylinder 67. The jaws 68 have contact surfaces 68C which are inclined from vertical. Specifically, in the view of FIG. 4, the right contact surface 68C would be inclined rightwardly at its upper end and left contact surface 68C would be inclined leftwardly at its upper end. In that fashion, opposing jaws 68 may firmly wedge tie plate P against the rail R. The jaws 68 of FIG. 4 are the field jaws on one side of the track, it being understood that identical gauge jaws would hold the gauge side of the plate P and that identical field and gauge side jaws would be mounted on the other side of the vehicle. There would be 4 jaws 68 associated with each rail R for a total of 8 jaws 68 on the apparatus 16.
Turning to FIGS. 2, 3, and 5 in conjunction, a tie guide 70 is movable up and down by tie guide lifter actuators 72 which have their barrel ends pivotably attached to plates 74. The plates 74 are fixed to member 32 of apparatus frame 18. The rod ends of actuators 72 are pivotably attached to member 76 connected to the remainder of tie guide 70 by members 78.
As best shown in FIG. 5, tie guide 70 is also attached to the member 30 of apparatus frame 18 by four bar linkages made of links 80 and adjustable links 82 (only one of each visible in FIG. 5), which maintain the orientation of tie guide 70 when it is moved up and down by actuators 72. Plates 84 are fixed to member 76 to move up and down with tie guide 70. Bolts 86 are mounted thereon to serve as an adjustable stop by hitting a portion of plate 88 fixed to member 32 when the tie guide 70 is dropped to a lower guiding position relative to the apparatus frame 18.
A central portion 90 of tie guide 70 includes a series of rollers 92 free to rotate about axes perpendicular to the lengthwise direction of tie T and front and back side plates 94 at each side, the side plates 94 having wide mouths and being tapered inward to direct the tie T into the space therebetween without binding. The space between side plates 94, which serve as side members, is considered as a tie channel extending transversely to a rail direction and into which a tie is channeled when it is inserted, as clearly shown in FIG. 5. Rollers 92 are mounted to chains 92C (see visible one in FIG. 3) which are unpowered, but help minimize friction between the bottom of tie guide 70 and the top of a tie T being inserted (see FIG. 5). As with the other portions of apparatus 18, the tie guide 70 is symmetric about a central axis (not shown) extending lengthwise between and parallel to rails R.
With reference to FIGS. 3, 6, and 7 in conjunction, a hydraulic sweeper 96 on each side has nine sweep paddles 96P (shown schematically in FIG. 7, left out of FIG. 3 for ease of illustration) which turn about central axis 96A. They may follow a circular pattern, an oval pattern with major axis horizontal, or, as shown, an oval pattern with major axis being vertical. In any case, the paddles 96P sweep ballast or other debris off new ties as they are inserted. The top view of FIG. 6 shows that the paddle 96P sweeping over the top of tie T in direction 96M is inclined to push debris leftwardly, off the tie and towards the unshown central axis between the two rails R. By having the sweep elements or paddles 96P sweep towards the central axis, debris is kept away from the rails R. The paddles 96P are 1/4 inch steel mounted to parallel hydraulically powered chain drives 98 (FIG. 3). The chain drives 98 are supported by the members 100 which are part of tie guide 70.
The operation of the apparatus 18 will now be described. The vehicle 10 moves to the tie to be removed. During this movement, the hydraulic valves (not shown) controlling the apparatus frame lifter actuators 22 are in the floating mode such that apparatus frame 18 can freely move up or down as it rolls on rails R. When the tie guide 70 and plate holders 38 are over a tie to be removed, actuators 22 cause frame 18 to press downwardly. At the same time, plate holder actuators 42 move plate holders 38 from their upper positions to their lower positions. Jaw actuators 67 are then retracted to bring four grip elements or jaws 68 against each of the two tie plates corresponding to the tie being replaced. The springs 60 insure that, when beginning to grip a tie plate, each pair of mechanical grip elements will automatically center about the tie plate prior to securely gripping the tie plate and without moving the tie plate. In other words, the springs 60 cause jaws to float at opposite ends of shaft 69 and tend to equalize force on both opposed jaws 68. Frame lifters 22 are returned to the floating mode and reduced pressure is supplied to tend to lift plate holders 38 which now hold the plates P. When the rail is lifted using the process described in the incorporated by reference patents, the plate holders 38 hold the tie plates P against the bottoms of the rails R. Floating of the frame lifter actuators 22 at this time avoids hindering removal of the old tie.
Before the new tie is inserted, pressure is applied to guide lifters or actuators 72 which lowers tie guide 70 into its lower or tie guiding position. Tie guide 70 is moved down to the position determined by the bolts 86. Tie sweepers 96 are activated to sweep and prevent ballast from getting between the tie T and tie plates P. The new tie T is now inserted.
After the new tie is inserted, plate hold or clamp actuators 67 are extended such the jaws 68 release the plates P. Before that happens, the plates P are automatically centered relative to tie guide 70 by operation of springs 60. Therefore, they will be centered relative to the central axis of the new tie being inserted and best positioned for attachment to the new tie. After jaws 68 release the plates, plate holder lift actuators 42 are extended to lift plate holders 38 and tie guide lift actuators 72 are retracted to lift tie guide 70 such that the vehicle may move to the next tie to be replaced.
When the vehicle is to travel long distances without replacing ties, actuators 22 are extended to lift the frame 18 relative to the vehicle frame 10M.
When moving between ties to be replaced, an operator may manually control the position of the vehicle. Alternately, a sensing system (not shown) may index or move the vehicle between ties. Such a sensing system is shown and described in U.S. Patent application of Newman et. al, Ser. No. 08/265,834, filed on Jun. 27, 1994, assigned to the assignee of the present application, and hereby incorporated by reference.
Although specific constructions have been presented herein, it is to be understood that these are for illustrative purposes only. Various modifications and adaptations will be apparent to those of skill in the art. In view of possible modifications, it will be appreciated that the scope of the present invention should be determined by reference to the claims appended hereto. | An apparatus grips tie plates and guides new ties during replacement of worn out ties in the road bed of a railroad track. Mechanical grip elements grip tie plates and secure them against the rail, while an old tie is removed and a new tie is inserted. A spring arrangement automatically self-centers opposing pairs of grip elements. That is, when beginning to grip a tie plate, each pair of mechanical grip elements will automatically center about the tie plate prior to securely gripping the tie plate and without moving the tie plate. The grip elements are supported by an apparatus frame. A frame lifter moves the apparatus frame vertically between an upper and a lower position relative to a vehicle frame of a tie replacer vehicle. A tie guide includes rollers on the underside thereof for minimizing friction between ties being inserted and the tie guide. Sweepers are mounted to the apparatus frame to clean off a tie as it is being inserted. | 4 |
TECHNICAL FIELD
The invention relates to a staple feeder shoe and door system for the magazine of a staple driving tool, and more particularly to such a system wherein the staple feeder shoe and door are reversible enabling quick and easy set-up of the tool for right or left-handed loading.
BACKGROUND ART
While the teachings of the present invention may be applicable to the magazine of many types of home and industrial fastener driving tools, for purposes of an exemplary illustration, the invention will be described in its application to an industrial staple driving tool.
Prior art workers have devised numerous staple driving tools and magazines therefor. In many types of jobs, it is imperative that the staple driving tool operator be able to reload staples into the tool magazine easily, quickly and efficiently. This is so that there will be little or no time lost in a piecework operation, or that staple drivings will not be missed in an assembly line operation.
There are many types of staple driving tool magazines requiring different loading procedures and manipulations. Top loading magazines, bottom loading magazines and end loading magazines are all well known in the art. In general, these three types of magazines can be loaded by left-handed and right-handed operators with equal facility.
The so-called top-side loading magazine, on the other hand, is generally designed or set-up for right-handed loading and is difficult and awkward for a left-handed operator to load. The top-side loading magazine generally comprises an elongated rail straddled by a row or stick of staples and a feeder shoe located behind the staples. A resilient member is provided to constantly urge the feeder shoe, and thus the row of staples, forwardly so that the forwardmost staple of the row is located in the drive track of the tool guide body, ready to be driven. An elongated door is provided, which is swingable between an open position and a closed position wherein the door at least partially overlies the top surface of the rail, assuring that the row of staples mounted thereon cannot fall off of or become dislodged from the rail when the tool is used other than in a substantially upright position. To reload this sort of magazine, it is necessary to pull the feeder shoe to its rearwardmost position, open the door and insert the staples inwardly and downwardly over the rail from one side of the tool. When a magazine of this sort is designed for a right-handed person and is manipulated by a right-handed person, it can be quickly and easily refilled with staples. However, this same magazine would be difficult and awkward to load by a left-handed operator. The only alternative would be to provided the magazine in both left-handed and right-handed models.
The present invention is based upon the discovery that if a top-side loading magazine is provided with a reversible door and a reversible shoe, the staple driving tool can be quickly and easily set-up for use by a left-handed or right-handed operator, utilizing a minimum of parts and without the necessity of having left-handed and right-handed models or specific left-handed and right-handed parts.
DISCLOSURE OF THE INVENTION
According to the invention, there is provided a reversible feeder shoe and door system for the magazine of a staple driving tool, which enables the tool to be set-up for right or left-handed loading.
The tool magazine comprises an elongated rail. The rail terminates at its foward end at the guide body of the tool. A row or stick of staples is slidably mounted in straddling fashion on the rail with the staple crown portions being supported by the top surface of the rail and the staple legs extending downwardly on either side of the rail. A feeder shoe, having a substantially symmetrical, inverted U-shaped body, is slidably mounted on the rail in straddling fashion behind the row or stick of staples. A resilient member constantly urges the feeder shoe forwardly on the rail, so that the forwardmost staple of the row or stick is located in the guide body drive track.
While not required, the magazine may include a U-shaped elongated body in which the rail is mounted. The elongated magazine body is mounted at its forward end to the guide body and is mounted at its rearward end to a portion of the tool body.
An elongated door extends substantially the length of the magazine and is swingable between an open position exposing the top of the rail and a closed position overlying the top of the rail to prevent inadvertent dislodgement of the staples from the rail when the tool is used other than in an upright position.
The feeder shoe has an operating handle extending laterally from one side thereof. The operating handle may be provided with a cap for ease of grasping. The feeder shoe has a lug extending laterally from the side opposite the operating handle side. When the shoe is manually shifted to its rearwardmost position on the rail through the use of the operating handle, the feeder shoe lug engages a portion of the door, shifting the door to and releasably locking the door in its open position, while at the same time locking the feeder shoe in its rearwardmost position for loading.
The feeder shoe is reversible on the rail so that its operating handle can be grasped by the left hand or the right hand of the operator. The door is reversible, being mountable in parallel-shaced relationship with either side of the rail.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a side elevational view of an exemplary industrial staple driving tool having a magazine provided with the reversible shoe and door system of the present invention.
FIG. 2 is an exploded perspective view of the magazine of FIG. 1, illustrating the various parts thereof, and including the tool guide body.
FIGS. 3, 4 and 5 are, respectively, plan, end and side elevational views of the feeder shoe of the present invention.
FIG. 6 is a fragmentary cross-sectional view taken along section line 6--6 of FIG. 5.
FIG. 7 is a cross-sectional view taken along section line 7--7 of FIG. 4.
FIG. 8 is a plan view of the rail of the present invention.
FIG. 9 is a side elevational view of the rail of FIG. 8.
FIG. 10 is an end elevational view of the rail of FIG. 8.
FIGS. 11 and 12 are end elevational views of the magazine with its end cap removed, illustrating the feeder shoe and door in left and right-handed configurations, respectively.
DETAILED DESCRIPTION OF THE INVENTION
FIG. 1 illustrates an exemplary industrial staple driving tool provided with a magazine having a reversible door and feeder shoe system in accordance with the present invention. It will be understood by one skilled in the art that the nature of the staple driving tool does not constitute a limitation on the present invention. The teachings herein are applicable to many types of fastener driving tools.
The staple driving tool is generally indicated at 1 and has a body 2 with a main cylinder portion 3, a handle portion 4 and a rearward portion 5. The tool 1 is illustrated as being of the fluid actuated type, having a fitting 6 for connection to a source of compressed air or the like. The main cylinder portion 3 of body 2 contains the main cylinder surmounted by the main valve and containing a piston-actuated driver (none of these elements being shown). A manual trigger 7 actuates the stem 8 of a remote valve 9, which in turn controls the main valve.
A guide body 10 contains the driver track (not shown). A staple is located in the driver track and the staple driver, when the tool is actuated, shifts downwardly in the driver track with great force, driving the staple into a workpiece. While an air-actuated tool is shown at 1, the tool could be of the electro-mechanical type, wherein the driver is driven by a solenoid, one or more flywheels, or the like.
Reference is now made to FIGS. 1 and 2. In these Figures, the magazine is generally indicated at 11. The basic components of the magazine 11 comprise a body generally indicated at 12, an end cap for the body generally indicated at 13, a rail generally indicated at 14, a feeder shoe generally indicated at 15, and a door generally indicated at 16. The remaining parts of the magazine will be described in their turn.
The magazine body 12 comprises an elongated member of U-shaped cross-sectional configuration. The body 12 is preferably made of metal, but could be extruded or molded of plastic or the like.
At its forward end, the body 12 has a pair of extensions 17 and 18, provided with coaxial perforations 19 and 20, respectively. The extensions are adapted to lie to either side of the tool guide body 10. The tool guide body 10 has a threaded perforation on each side, corresponding to body perforations 19 and 20. One of the guide body perforations is shown at 21. The magazine body 12 is affixed to the guide body by means of a screw 22 passing through magazine body perforation 19 and into the threaded perforation 21 of guide body 10. A similar screw 23 passes through magazine body perforation 20 and into the other threaded perforation (not shown) of guide body 10. When fastened in place, the forward end of the magazine body 12 abuts the rearwardly facing surface of guide body 10.
At its rear end, the magazine body has a pair of coaxial perforations 24 and 25. The rearward portion 5 of tool body 2 has an extension 5a which lies to one side of magazine body 12 (see FIG. 1). A bolt 26 passes through a perforation in body extension 5a and through the coaxial perforations 24 and 25 of the magazine body 12 to complete the mounting of the magazine body 12 to the tool 1. Bolt 26 is provided with a nut 27.
As is evident from FIGS. 1 and 2, the forward end of magazine body 12 is closed by the tool guide body 10. The rearward end of the magazine body 12 is closed by the end cap 13. The end cap 13 has a body portion 28 receivable within the rearward end of magazine body 12, and a rear wall portion 29 which abuts the rearward end of magazine body 12. The body portion 28 has a perforation 30 therethrough which, when the end cap 13 is in place, is coaxial with the magazine body perforations 24 and 25 so that bolt 26 extends therethrough, maintaining the end cap 13 in place. The end cap 13 may be made of metal, but lends itself well to be molded of an appropriate plastic material.
The rail 14 is best shown in FIGS. 8 through 10. As viewed in these Figures, the rail 14 has a longitudinal body 31 of uniform thickness surmounted by a longitudinally extending head or cap portion 32 providing the top surface 33 of rail 14. The body 31 has three opposed pairs of laterally extending ribs 34-35, 36-37 and 38-39. It will be noted that the pair of ribs 36-37 are rounded on their underside as at 36a and 37a. The purpose of this will be apparent hereinafter.
The ribs 34-35, 36-37 and 38-39 extend substantially the length of rail 14 and serve two purposes. First of all, they strengthen the rail. Secondly, they help support a row of staples mounted on rail 14. In FIG. 10, the last staple 40a of a row or stick of staples 40 is shown mounted on rail 14. The staple 40a straddles rail 14 with its crown portion 40b supported on the rail top surface 33 and its legs 40c and 40d, depending downwardly alongside rail 14. As configured, rail 14 is adapted to support staples of the same width, but of three different leg lengths. Staple 40a, as illustrated, is of an intermediate length. It will be noted that its legs 40c and 40d extend slightly below the rib pair 36-37. A short leg length staple will have legs extending slightly below rib pair 34-35 and a long leg length staple will have its legs extending just below rib pair 38-39. It will be apparent from FIG. 9 that ribs 34 and 36 terminate just short of the forward edge of rail 14. This is also true of ribs 35 and 37.
Returning to FIG. 2, it will be noted that guide body 10 has a pair of vertical, rearwardly extending walls 41 and 42, notched as at 41a and 42a, respectively, and a horizontal wall 43. When the magazine 12 is assembled and affixed to guide body 10, the forward end of magazine body 12 slips between horizontal wall 43 and the bottom ends of vertical walls 41 and 42. The forward end of rail 14 is received between and supported by guide body walls 41 and 42. The forward end of cap 32 of rail 14 rests upon the upper ends of walls 41 and 42. The short ribs 34-35 and 36-37 abut the walls 41 and 42. The ribs 38 and 39 are received within wall notches 41a and 42a. The bottom edge of rail 14 rests upon the bottom inside surface of magazine body 12.
As shown in FIG. 9, the rearward end of rail 14 is notched, as at 44. Returning again to FIG. 2, the body portion 28 of end cap 13 has an upper portion 28a with a socket (not shown) formed therein, an intermediate portion 28b with perforation 30 formed therein, and a lower portion 28c having a socket (not shown) formed therein. The socket in upper portion 28a is adapted to receive a resilient pad 45. Similarly, the socket in lower end cap body portion 28c is adapted to receive a resilient pad 46. When the end cap 13 is mounted in place within magazine body 12, that rear end portion of rail 14 above notch 44 is received within the socket in the upper end cap body portion 28 and that rear end portion of rail 14 below notch 44 is received within the socket in the lower end cap body portion 28c. Thus, the rail 14 is fully supported by the walls 41, 42 and 43 of guide body 10, by the lower inside surface of magazine body 12, and by the sockets in body portions 28a and 28c of end cap 13. It will be evident that notch 44 accommodates the body portion 28b of end cap 13, making room for perforation 30 therein and the bolt 26 (FIG. 1) joining magazine body 12, end cap 13 and the lower rear body extension 5a of tool 1.
The feeder shoe 15 is best seen in FIGS. 3 through 7. The feeder shoe 15 has an inverted U-shaped body 47 comprising an upper base portion 48 and downwardly depending legs 49 and 50. The base portion 48 has a central depressed portion 51 providing an under surface 52 adapted to rest upon and slide along the upper surface 33 of rail 14.
Leg 49 has a rectangular opening 53 from which is formed an inwardly extending arcuate lug 54. The inwardly extending arcuate lug 54 is clearly shown, for example, in FIG. 6. The lug 54 constitutes an integral part of leg 49. The leg 49 also has an opening 55 therein, from which is formed the integral handle 56. The handle 56 has a perforation 57 formed therein. As is shown in FIG. 2, the end of handle 56 may be provided with a cover member 58 of plastic or other suitable material, held in place by means of a rivet 59 (or other appropriate fastener) passing through handle perforation 57. The cover 58 makes handle 56 more comfortable to manipulate.
The feeder shoe leg 50 has an opening 60 equivalent to the opening 53 in leg 49. This enables the formation of integral lug 61. The lug 61 extends inwardly and is of arcuate configuration, being equivalent to lug 54 of leg 49.
To complete the feeder shoe, there is a second opening 62 in leg 50, enabling the formation of integral feeder shoe tab 63. As is most clearly seen in FIG. 3, the tab 63 has an arcuate peripheral edge with a notch 64 formed centrally therein. The purpose of tab 63 and its notch 64 will be explained hereinafter.
As will be evident from FIGS. 2 and 11, the feeder shoe 15 is so sized as to straddle rail 14 with the under surface 52 (see FIG. 4) of its base portion 48 riding along the top surface 33 of rail head 32 and its legs 49 and 50 depending along side rail 14. The arcuate lugs 54 and 61 of feeder shoe 15 extend beneath the curved under sides 36a and 37a of rail ribs 36 and 37. The feeder shoe 15 may be mounted on rail 14 from either end and is slidable thereon. Once rail 14 is mounted within magazine body 12 between guide body 10 and end cap 13, the feeder shoe lugs 54 and 61 render the feeder shoe captive on the rail. It will be noted from FIG. 11 that the feeder shoe handle 56 extends above and beyond the adjacent side of magazine body 12. FIG. 12 is similar to FIG. 11 and clearly illustrates that feeder shoe 15 can be reversed on rail 14, i.e. mounted on rail 14 with its handle 56 extending to the right of the rail as viewed in FIG. 12, rather than to the left of the rail as viewed in FIG. 11. Thus, feeder shoe 15 can be mounted on rail 14 with handle 56 in positions wherein its handle 56 can be readily grasped by the right hand of the operator, or by the left hand of the operator.
As is evident from FIGS. 1 and 2, the feeder shoe is located on rail 14 behind the stick of staples 40. The function of the feeder shoe 15 is to constantly urge the stick of staples 40 forwardly on rail 14 so that the forwardmost staple of the stick is located within the drive track (not shown) of the tool guide body 10. The forward urging of the feeder shoe 15 can be accomplished in any appropriate manner, including the use of a spring member or other resilient means.
In FIGS. 1 and 2, the means for constantly urging the feeder shoe 15 forwardly on rail 14 is illustrated as comprising an elastomeric cord 65. One end of cord 65 is anchored at the rearward end of magazine 11. While this can be accomplished in any appropriate way, a simple expedient is simply to cause the cord 65 to pass through an opening in end cap 13, whereupon the cord is knotted as at 66 (see FIG. 2).
The cord 65 passes about a freely rotatable pulley at the forward end of magazine body 12. Such a pulley is shown in FIGS. 1 and 2 at 67, rotatively mounted on an internally threaded hub 68. A screw 69, provided with a lock washer 70, passes through a perforation 71 in the side of magazine housing 12 and into threaded engagement with pulley hub 68. The free end of elastomeric cord 65 has an elongated hook 72 crimped or otherwise appropriately affixed thereto. As is evident from FIG. 1, the hook 72 and cord 65 pass behind feeder shoe leg 49 and in front of feeder shoe leg lug 54, engaging feeder shoe leg 49. As a result of this arrangement, the elastomeric cord 65 constantly urges feeder shoe 15 (and the stick of staples 40) forwardly along rail 14, toward tool guide body 10.
When feeder shoe 15 is mounted on rail 14 in the manner shown in FIG. 12, the hook 72 of elastomeric cord 65 can engage feeder shoe leg 50 in the same manner. Alternatively, the magazine body 12 may be provided with a perforation (not shown) coaxial with and equivalent to the perforation 71 in the opposite wall of magazine body 12. Thus, the pulley 67 and its hub 68 could be mounted on the opposite wall of magazine body 12, so that when feeder shoe 15 is mounted in the manner illustrated in FIG. 12, the hook 72 of elastomeric cord 65 can engage feeder shoe leg 49.
The magazine 11 is completed by the provision of door 16. In the embodiment illustrated, the door 16 is shown as being formed of rod stock. The door 16 has an elongated rectilinear portion 73 of a length equal to the majority of the length of rail 14, as can readily be seen in FIGS. 1 and 2. At its rearward end, as viewed in FIG. 2, the rectilinear portion 73 terminates in a laterally extending portion 74 which, in turn, leads to a downwardly depending portion 75. The downwardly depending portion 75 terminates in a laterally extending portion 76, parallel to the portion 74. The portion 76 leads to a portion 77 parallel to the rectilinear portion 73. The portion 77 terminates in a lateral portion 78, equivalent to portion 76. The portion 78 terminates in a portion 79 which is vertical and equivalent to the portion 75. Finally, the portion 79 ends in a lateral portion 80 which extends transversely of the magazine and slopes slightly upwardly, as can best be seen in FIG. 11. The portion 80 constitutes a release arm, as will be apparent hereinafter. It may be provided with a sheath 81 of plastic, rubber or other appropriate material, rendering it more easily and comfortably actuable by the finger of the operator.
The end structure of door 16, at the opposite or forward end of the elongated rectilinear portion 73, is a mirror image of the end portion just described. Thus, at the left hand end of elongated rectilinear portion 73 (as viewed in FIGS. 1 and 2), there are portions 82 through 88, constituting the full equivalent of portions 74 through 80, respectively.
In FIGS. 1, 2 and 11, the tool 1 and/or its parts are shown for set-up as a left hand loading tool. Under these circumstances, the portions 86, 87 and 88 of door 16 are not needed and are cut or severed from the door and discarded. As a result of this, portions 86, 87 and 88 are illustrated in broken lines in FIG. 2.
The magazine assembly is completed by the provision of first and second spring members. The first spring member is indicated at 89 in FIG. 2. Spring member 89 is made of resilient spring metal and comprises a platelike portion 90 having a pair of perforations 91 and 92 therein. One end of the portion 90 has an inwardly and longitudinally extending resilient tine 93 terminating in a hook-like configuration 94. The spring member 89 is affixed to the inside surface of the right side of magazine body 12. To this end, the magazine body 12 is provided with perforations 95 and 96, coaxial with spring member perforations 91 and 92. A pair of screws 97 and 98 pass through the spring member perforations 91 and 92 and the magazine housing perforations 95 and 96 and are engaged by nuts 99 and 100, respectively. The opposite or left side of magazine housing 12 is provided with a pair of perforations 101 and 102, equivalent to and coaxial with perforations 95 and 96, for use when the door is to be mounted for right hand loading, as will be described hereinafter.
The second spring member is shown at 103. It comprises an elongated plate-like member of resilient spring metal having a pair of inwardly and longitudinally extending tines 104 terminating in hook-like portions 105 and an inwardly and downwardly extending tine 106. At its forward end, spring member 103 is provided with a perforation 107, and the adjacent side of magazine body 12 is provided with a corresponding perforation 108, enabling the spring member 103 to be affixed to the magazine body 12 by screw 109 and nut 110. At its rearward end, the spring member 103 is provided with a perforation 111 which is coaxial with perforations 25 of the magazine body 12. Thus, the spring member 103 is also held in place by the bolt 26 and nut 27 (see FIG. 1). The opposite or left side of the magazine body 12 is provided with a perforation 112, equivalent to perforation 108, and used when the door is to be mounted for right hand loading, to be described hereinafter.
When the door 16 is installed, its portion 85 is located in a notch 113 in guide body 10. This engagement constitutes one hinge point for the door 16. At the other end of door 16, the portion 77 thereof is engaged beneath the inwardly and downwardly extending resilient tine 106 of spring member 103 (see FIG. 11), and this engagement constitutes the other hinge point of door 16. When so mounted, the hook-like portion 94 of the resilient tine 93 of spring member 89 engages door portion 83 at the forward end of the door. At the rearward end of the door 16, the hook-like portion 105 of one of resilient tines 104 of spring member 103 engages door portion 75. In this manner, tines 93 and 104 constantly urge the door 16 to its closed position. Door 16 is shown in its closed position in FIG. 11 with the elongated, rectilinear door portion 73 overlying feeder shoe 15. Thus, it will be evident that door portion 73 will also overlie the stick of staples 40 located on rail 14 ahead of feeder shoe 15, retaining the stick of staples 40 in place on the rail, regardless of the orientation of tool 1 during use.
The operation of the reversible feeder shoe and door system of the present invention will now be described with respect to FIGS. 1, 2 and 11. It wll be remembered that, in these Figures, the reversible feeder shoe 15 and door 16 have been set-up for left hand loading.
With particular reference to FIGS. 1 and 11, to load the magazine 11 of tool 1, the operator grasps the handle 56 of feeder shoe 15 with his left hand and pulls the feeder shoe rearwardly of magazine 11 along rail 14. As feeder shoe 15 approaches the rearward end of magazine 11, the arcuate peripheral surface of feeder shoe tab 63 (see FIG. 3) will engage door portion 75 (see FIG. 2) and will cam the door to its open position. When the feeder shoe 15 is fully retracted on rail 14, the notch 64 of tab 63 (see FIG. 3) will engage door portion 75 (see FIG. 2), and this engagement will serve two purposes. First of all, it will lock the feeder shoe in its rearwardmost position. At the same time, however, it will lock door 16 in its open position.
When door 16 is pivoted to its open position, it will pivot in a clockwise direction (as viewed in FIG. 11), and the elongated, rectilinear door portion 73 will clear and no longer overlie the head portion 32 of rail 14. As a result, a stick of staples 40 can be inserted from the left hand side of of tool 1 inwardly and downwardly into position on rail 14. Once a stick of staples has been located on rail 14, the operator applies a slight lifting force to the release arm portion 80 of door 16. This will remove door portion 75 from the notch 64 in the feeder shoe tab 63 and the feeder shoe will shift forwardly along rail 14 under the urging of elastomeric cord 65 until the forwardmost staple of the stick has entered the drive track (not shown) of guide body 10. The feeder shoe 15 having shifted forwardly, the door is now free to be returned to its staple-retaining, door-closed position shown in FIG. 11, under the urgings of resilient tines 93 and 104. The tool 1 may then be used by the operator until all of the staples of the stick 40 have been drive, whereupon the quick and easy reloading procedure is repeated.
To initially set-up tool 1 for right loading, it is only necessary to follow a few simple steps. The feeder shoe 15 is reversed in position on rail 14 so that its handle 56 extends to the right of the tool. The elastomeric cord 65 is attached to the feeder shoe by means of its hook 72, in the manner described above. If desired, the pulley 67 may be mounted on the right side of magazine body 12. The first spring member 89 is mounted on the left side of magazine body 12, utilizing perforations 101 and 102 in the magazine body.
The door 16, for right hand loading, will be hingedly affixed to the left side of the magazine body 12. Under these circumstances, the door portions 86, 87 and 88 will be left intact, and the door portions 78, 79 and 80 will be removed from the door and discarded. The sleeve 81 is mounted on door portion 88. The door is mounted to the left side of the magazine body 12 in precisely the same manner as described with respect to FIGS. 1, 2 and 11. In this instance, the now forward portion 77 of door 16 will be received within the notch 114 of guide body 10. The notch 114 is equivalent to and lies directly opposite the guide body notch 113.
The staple loading procedure for right hand loading will be substantially identical to that described with respect to left hand loading, differing only in that the feeder shoe handle 56 and the door release arm 88 will be manipulated by the operator's right hand. Similarly, the stick of staples will be inserted inwardly and downwardly from the right of the tool.
Modifications may be made in the invention without departing from the spirit of it. For example, the door 16, in the exemplary embodiment, has been illustrated as being made of rod stock. It would be within the scope of the present invention to provide a sheet metal door or the equivalent molded of appropriate plastic, or the like.
Finally, it would also be within the scope of the present invention to eliminate the magazine body 12. Under these circumstances, the door 16 would have to be hinged to the bottom of rail 14 or to appropriate parts of body 2 of tool 1. The pulley 67 could be appropriately mounted on rail 14, so as to provide clearance for feeder shoe 15. Alternatively, some other form of resilient means could be used to urge the feeder shoe forwardly. | A reversible feeder shoe and door system for the magazine of a staple driving tool enabling set-up of the tool for right or left handed loading. The tool magazine comprises an elongated rail terminating at its forward end at the guide body of the tool. A row of staples is slidably mounted in straddling fashion on the rail. A feeder shoe, having a substantially symmetrical inverted U-shaped body, is slidably mounted on the rail in straddling fashion behind the row of staples. A resilient member constantly urges the feeder shoe forwardly so that the forwardmost staple of the row is located in the guide body drive track. The magazine may include a U-shaped elongated body in which the track is mounted. An elongated door is provided, swingable between an open position exposing the rail top and a closed position overlying the rail top to prevent inadvertent dislodgement of the staples from the rail. The feeder shoe has an operating handle extending laterally from one of its sides and a lug extending laterally from the other of its sides. When the shoe is shifted to its rearwardmost position on the rail by the operating handle, the lug engages a portion of the door, opening the door and releasibly locking the door in its open position, the feeder shoe being also releasibly locked in its rearwardmost position for loading. The feeder shoe is reversible on the rail so that its operating handle can be grasped by the left or right hand of the operator. The door is reversible, being mountable in parallel spaced relationship to either side of the rail. | 1 |
SUMMARY OF THE INVENTION
The present invention relates to a dismantling ladder which can be stored in a minimum amount of space yet one which is very strong.
Although the ladder of the present invention was primarily designed for use by owners of mobile homes, it is obvious that the invention is one of wide applicability and can be used in any instance wherein it is desired to provide a strong ladder which can be disassembled and stored in a minimum amount of space.
Various ladders have been proposed in the past of a folding or telescoping nature but in each instance, the strength of the ladder depends on the fastening elements which hold the ladder in extended position. For instance, a number of ladders have been proposed having a pair of rails divided into sections wherein each section is smaller than the next lower so that a number of sections can be telescoped when the ladder is not in use. However, such ladders are dependent upon the snaps or clips which hold the rails in an extended position so that should these fastening means collapse, the ladder itself will collapse. Such unsafe structures have never been commercially successful because of this lack of safety. The ladder of the present invention can be stored in a much smaller space.
Further, with such telescoping ladders, the minimum dimension of the stored package is somewhat more than the height of one section and the width is as wide as the ladder itself.
Thus, the ladder of the present invention can be shipped and stored in a minimum amount of space yet it is extremely strong and does not depend on a fastening means for strength.
In contrast, the ladder of the present invention is extremely strong since the sections are held in an extended position by positive metallic stops and the clips which are employed merely hold the ladder together so that it can be readily moved without falling apart from one place to another. In other words, even if one of the clips failed, the ladder itself would not become unsafe.
Other objects and features of the invention will be brought out in the balance of the specification.
BRIEF DESCRIPTION OF THE DRAWINGS
In the drawings forming part of this application:
FIG. 1 is a perspective view of a ladder embodying the present invention.
FIG. 2 is an enlarged section of one of the rails of the ladder.
FIG. 3 is a perspective view of the disassembled parts employed in making the ladder of the present invention.
FIG. 4 is a section of a telescoped assembly, including two rails and a rung.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring now to the drawings by reference characters, the ladder of the present invention basically includes a plurality of large rails 5, a plurality of small rails 7, and a plurality of rungs 9. As is best seen in FIGS. 3 and 4, the inner diameter of a large rail 5 fits into the outer diameter of a smaller rail 7 and the inner diameter of the smaller rail 7 is such that it will accomodate the rung 9.
The rungs 9 fit into holes 11 and 13 in the rails 5 and 7 respectively. It will be noted that the holes 11 and 13 are somewhat square while the ends of the rungs have been flattened down as at 15 and 17 so that the rungs will not turn when they are stepped on.
In the embodiment of the ladder illustrated, the rails are shown as being two steps high although, of course, they could be of three steps or other multiples, depending upon the minimum height one had available for storage and shipment.
Between adjacent sections of the rails are the connecting sections generally designated 19 and these consist of two T-shaped ends 21 and 23 with a rung 25 attached between them. Since these are not ordinarily disassembled, they can be permanently assembled by means of welding or by use of bolts as at 27. The T sections, as is most clearly seen in FIG. 2, have a collar 29 fixed, as by welding, on the inside, so that this collar supports the weight of adjacent sections. In addition, the rails are provided with a hole 24 which mates with a spring-mounted pin 28 to hold adjacent sections together. However, it will be apparent that the weight of the ladder, and anyone standing on the ladder, is borne by the collar 29 pressing against the next lower rail, so that the pins 28 are not relied upon to hold any weight but are merely used to facilitate movement and initial assembly of the ladder.
In addition to the connecting sections such as those designated 19, special sections may be used at the top and the bottom, although they are not strictly necessary for the purposes of the present invention. As is shown in FIG. 1, section 30 has angling members 31 and 33 supporting short arms 35 and 37 which can be employed at the top of the ladder for the purpose of holding weight distributing feet 39 and 41. Such an upper terminating section may not be employed when the ladder is used for many purposes but it is likely desirable when it is used with an inherently weak structure such as a mobile home. In addition, a special bottom section 40 can be employed which is similar to that shown at 19 except that it has weight distributing feet 43 and 45, preferably provided with antifriction pads 47.
The ladder can easily be disassembled merely by pulling out on the springs holding the pins 25 and lifting the sections apart. This will produce the plurality of parts shown in FIG. 3. It will be noted that the short arm 37 telescopes within the short arm 35 while each of the rungs 9 fits inside of a small rail 7 which in turn fits inside of a large rail 5. Thus, the parts can be stored in a minimum of space and will occupy much less room than telescoping-type ladders.
Many variations can be made in the exact structure shown without departing from the spirit of this invention. For instance, a ladder with 9 rungs as shown and obviously the ladder can be made with any desired number of rungs. Further, the ladder is divided into sections, each twice as high as a single step, but the ladder can be divided into sections of three or even more steps. The holding devices have been shown as spring mounted pins but these are not essential to the operation of the ladder and merely serve as a convenience in assembling and moving the ladder. Any suitable locking device might be used. Although the rails and rungs have been shown to be round, they can be of any shape. For instance, they can be made of a series of concentric squares which would fit together. The connectors 21 have been shown as fitting outside the rails and they can just as easily fit inside of the hollow rails.
It is believed apparent from the foregoing that we have provided a dismantable ladder which is strong and can be easily disassembled and stored in a minimum of space. | A dismantling ladder is provided wherein the rails are made of different sizes with the rungs of a still smaller size so that one rail can be telescoped inside the other and a rung telescoped inside the smaller rail so that the ladder can be stored in minimum of space. | 4 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to an administrator interface for a data base in a distributed data processing environment. It applies in particular to the supervision of the operation of a data base and to the detection of potential abnormal operations.
2. Description of Related Art
The current trend in the development of data processing systems is to form such a system by associating a plurality of machines or platforms connected to one another by means of a network, (LAN) for example a local area network. In the LAN, any user can run applications of extremely varied types on this group of machines. These applications call services which supply information required to handle the problem or problems they are working on, which are offered by all or some of these machines. A system of this type is called, in the most general designation a "distributed data processing environment", which one skilled in the art usually called a "site".
Each machine or platform is also called a "node" by one skilled in the art, and any process running on any of these machines is designated by the server name, and thus executes a given job on the server.
A data base may be defined as being an integrated data set which models a given environment. The data used by various applications is collected in the same base in order to avoid the problem of their duplication. A conceptual schema associated with a data base describes the structure and the type of data it contains and the constraints which must always be satisfied, the latter function being fulfilled by the data base administrator.
The structure of a data base is composed of a set of files which constitute the physical data storage medium. Three types of files are distinguished. The Data files ensure the storage of the objects created by the users of the base as well as those necessary to the operation of the base. The Redo Log files contain the most recent modifications of the data; they are used to return the data base to a consistent state, without losing the unsaved updates in the data files in case of a hardware or software failure. The Control files contain the information related to the structure of the data base, such as the name of the data base, the name and location of the Data files and Redo Log files, etc., and are updated each time a Data file or Redo Log file is created or renamed.
One of the most widely used data base management systems is the Relational Data Base Management System, often designated by its acronym RDBMS, known under the registered trademark ORACLE V7, produced by the company ORACLE Corp., which uses the standardized language SQL (Structured Query Language) and operates on a machine running the UNIX (trademark registered to Norrell, Inc.) operating system, the communication protocol used being the standardized protocol SQL*NET.
The internal architecture of ORACLE is organized into three levels. A first level, called a file level, corresponds to the structure of the data base and to the way in which the data is stored. A second level, called a storage level, corresponds to the organization of data in main storage; it is composed of a set of buffer areas allocated by ORACLE for containing the data and certain control information. Finally, a third level, called a process level, corresponds to the various Oracle processes which ensure the management of the data (as distinguished from the user-provided processes which ensure the execution of the applications submitted to ORACLE, and the DBMS processes which ensure the management of the data, for example data writing, checkpoint data writing, copying into archive files, etc.). A process is a mechanism of the operating system which makes it possible to execute a series of calculation and input/output operations. The role of the various ORACLE processes is to execute the actions entered by the applications and to exchange the data between auxiliary storage and main storage. The combination of the allocated storage areas and the processes constitutes an ORACLE instance. The latter can also be defined as a set of servers and associated storage spaces which ensures the access to and the integrity of the ORACLE data base. The machines and software programs which run on them and which operate with the ORACLE system are called objects.
Within the scope of the invention, it is assumed that this data base is used in a distributed data processing environment.
In terms of satisfying the constraints mentioned above, the management of the data has three roles of an organizational and technical order. First, it defines the users of the data base, giving each of them a name, a password and a set of privileges or rights to access the data. It also defines the administrator or administrators, who are the authorized persons responsible for it, either in part or in its entirety. Its second role is to assign the definition of the conceptual schema of this base to the administrator, or to have the administrator participate in its definition. The administrator therefore defines the schemas of the various tables and the rules related to these tables.
SUMMARY OF THE INVENTION
The object of the present invention is to provide an aid for the administrator which sees to the proper utilization of the data base and thus to the proper operation of its management system. It is particularly well adapted to the ORACLE system defined above.
The object of the invention is to offer a user-friendly administrator interface which allows the administrator to gain easy access to the current status of the objects in the base, as well as access to information related to each of these objects. Thus, the administrator is relieved of the work of performing a search on the current status of the base on the one hand, and of compiling the results of such a search on the other hand.
Thus, the invention relates to an administrator interface which works, by means of a graphical user interface, with a relational data base management system belonging to a distributed data processing environment comprising a plurality of machines connected to a network, and is characterized in that it comprises:
a plurality of folders which reflect the states of the network on the one hand and objects in this network on the other hand, at least relative to the Management, the Processes in the course of running, the Events which affect them, the Configuration, the Files, the command scripts also known as Scripts, and the Errors, this plurality comprising at least:
for each of the instances, a list of instance references attached to the nodes of the network, a list of process references and a list of event and trace file references, a list of parameters, lists of file references,
a list of scripts,
and means for allowing access to and/or manipulation of the folders.
According to another characteristic, the means are constituted by a window which makes it possible, by means of a menu bar, to select one of the folders in order to make a corresponding pane appear.
BRIEF DESCRIPTION OF THE DRAWINGS
The characteristics and advantages of the invention will emerge from the following description, given by way of example and illustrated in the appended drawings, in which FIGS. 1 through 14 represent the various windows and panes used by the administrator interface of the data base.
FIG. 1 illustrates an Administrator Interface screen;
FIG. 2 illustrates a Node information screen;
FIG. 3 illustrates an SQL Server information screen;
FIG. 4 illustrates an Instance information screen displaying basic information relating to the selected instance;
FIG. 5 illustrates a Management screen for controlling a list of instances managed by the interface;
FIG. 6 illustrates information on the processes related to the instance;
FIG. 7 illustrates an Events screen displaying information relating to the most recent events;
FIG. 8 illustrates a Configuration screen displaying a list of fields related to parameters of the instance;
FIG. 9 illustrates a Files screen displaying information on the configuration files related to the instance;
FIG. 10 illustrates a Scripts screen displaying information relating to the execution of a script;
FIG. 11 illustrates an Add screen displaying information relating to adding an existing script to the managed list of scripts;
FIG. 12 illustrates a Delete screen displaying information relating to removal or deletion of an existing script from the managed list of scripts;
FIG. 13 illustrates a Parameters screen displaying parameter fields to be defined to allow execution of scripts;
FIG. 14 illustrates an Error screen displaying information relating to error codes.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
As indicated above, the interface according to the invention preferably works with the ORACLE type of relational data base management system, more commonly designated by its acronym RDBMS.
In the exemplary embodiment described herein, the interface comprises seven folders which can be accessed and/or manipulated through it. The content of these is indicated below; they are the Management, Processes, Events, Configuration, Files, Scripts, and Errors folders.
This interface also includes a software program for the presentation and constitution of the folders. This software is connected by a link of the terminal to a mouse which makes it possible to cause external events. The mouse is, for example, the type with three buttons. The external events caused by the mouse are processed by a pre-programmed mouse interface incorporated into the software which can also recognize the pressing or release of a button, the dragging of the mouse, and logical events such as the entry of the pointer into a window or a field. On the screen, the position of the pointer of the mouse is indicated by a small arrow directed upward. Of course, without leaving the scope of the invention, the mouse could be replaced by any other pointing device such as a light pen or a graphic plotter. Finally, in addition to the mouse interface, an interface is also provided for a programmed keyboard, for the character keys as well as for the command keys and arrow keys, so that it is possible, in the edit mode, to enter the information which corresponds to different areas of different windows. The presentation software allows the display of the windows and the execution of actions selected on control buttons of a window as a result of the triggering of an external event, such as for example the operation of a mouse button. In the text which follows, it is implied that any selection operation will be effected by means of the mouse.
The display of the windows occurs through a graphical interface of the X/Motif (registered trademark) type.
The first window displayed, or the main window, after the connection with the server in the process of running in a given node is the window 1 (FIG. 1).
This window 1 includes a title bar 11, underneath which is a menu bar 12 that makes it possible to select one of the folders contained in the menu, namely Management 120, Processes 121, Events 122, Configuration 123, Files 124, Scripts 125 and Errors 126, the menu comprising a control button associated with each folder. Each of the folders makes it possible, by selecting it, to display another window.
The window 1 presents the state of the network by giving a current view of the following ORACLE objects: declared nodes in the network, state of the SQL server of each node, and declared instances in each node.
The window 1 includes a first field 13 which allows the display of a node name (Node), a second field 14 which allows the display of an instance name (Instance), and a box 15 with horizontal and vertical scroll bars. The box 15 includes a field 151 which indicates the current time references (Time).
In the box 15, each node in the distributed data processing environment (which one skilled in the art usually calls a "site", a term which will be used throughout the text which follows), is represented by a vertical rectangle 152. Each rectangle 152 includes an icon 1521 indicating the name of the node, an icon 1522 representing the state of the SQL server connected to the node, and possibly one or more icons 1523 indicating the possible instance or instances declared in this node.
To facilitate the understanding of the site by the administrator, the rectangle 152 will preferably be of a different color depending on whether or not the node is effectively connected to the network. Likewise, the icon representing the state of the corresponding server will be of a different color and/or have a different graphic depending on whether or not this server is accessible. Likewise, the icon or icons representing the corresponding instance or instances declared in the node, for example, will be of different colors depending on whether or not these instances are active.
By selecting an icon 1521 representing a node (for example, by pressing the middle button on the mouse when the mouse pointer is positioned over the icon), a pane 20 (illustrated in FIG. 2) is created in which basic information related to the selected node is displayed. At the same time, the name of the node is displayed in the field 13.
The pane 20 includes a title bar 21, a first field 22 indicating the name of the operating system (OS) used, a second field (23) indicating the name (Name) of the node in the network, a third field 24 indicating the release (Release) of the operating system, and possibly a fourth field 25 indicating the reference number (Version) of a version of the operating system, a fifth field 26 indicating the network address (machine ID) of the machine corresponding to the node, and a control button 27 (OK) which makes it possible to close the pane 20 (for example by pressing the middle button of the mouse, the mouse pointer being positioned over the button) and return to the main window 1.
By selecting an icon 1522 representing the SQL server running in a given node (for example by pressing the middle button of the mouse when the mouse pointer is positioned over the icon), a pane 30 (illustrated in FIG. 3) is created in which basic information related to the selected server is displayed. Simultaneously, the name of the node to which the server is connected is displayed in the field 13, in the case where this information was not displayed previously.
The pane 30 includes a title bar 31, a first field 32 indicating the reference number (Release) of the current ORACLE release, a second field 33 indicating the startup date (Started at) of the SQL server in the network, a third field 34 indicating the date (Last connection) of the last connection of the server to the network, a fourth field 35 indicating the total number of accepted connections (Total connections) of the server to the network, a fifth field 36 indicating the total number of rejected connections (Total rejections) of the server to the network, a sixth field 37 indicating the number of active subprocesses of the server (these are the subprocesses created for processing the requests submitted by user-provided processes connected to an instance, a user-provided process being responsible for the running of an application or an Oracle tool), a seventh field 38 indicating the length of the queue (Length of queue) of requests submitted to this server by users connected to the network, and a control button 39 (OK) which makes it possible to close the pane 30 (for example by pressing the middle button of the mouse, the mouse pointer being positioned over the button) and return to the main menu.
By selecting an icon 1523 representing an instance attached to a node (for example by pressing the middle button of the mouse when the mouse pointer is positioned over the icon), a pane 40 (illustrated in FIG. 4) is created in which basic information related to the selected instance is displayed. Simultaneously, the name of the node is displayed in the field 13 (if this has not already occurred), and the name of the instance is displayed in the field 16.
The pane 40 includes a title bar 41, a first field 42 indicating the reference number (Release) of the release of the instance, a second field 43 indicating the reference number (SQL release) of the current SQL release, a third field 44 indicating the size (Total System Global Area) of the system global area in octets (the system global area is a set of shared buffer areas which contain the data and control information related to an ORACLE instance shared among several users connected to it), also called SGA (System Global Area), a fourth field 441 indicating the fixed size (Fixed Size) of the system global area, a fifth field 442 indicating the variable size (Variable Size) of the system global area, a sixth field 443 indicating the size of the database buffers (Database Buffers) of the system global area, a seventh field 444 indicating the size of the redo buffers (Redo Buffers) of the system global area, an eighth field 45 indicating the reference (remote -- login -- passwordfile) of the file containing the password for connecting to the instance from a remote site, a ninth field 46 indicating the value of a parameter (remote -- os -- roles) which indicates the existence of roles related to the remote connection via the operating system, and a control button 47 (OK) which makes it possible to close the pane 40 (for example by pressing the middle button of the mouse, the mouse pointer being positioned over the button) and return to the main menu.
A role is an aggregation of data access rights and system privileges which increases security and significantly reduces the difficulty and the cost of administrating it, which aggregation can be allocated to users and/or to other roles. Generally, the application roles, which include all the privileges required to run an application, are distinguished from the user roles, which manage the common privileges required for the users of the base, such as login privileges.
By selecting the Management folder 120, (for example by pressing on the middle button of the mouse, the mouse pointer being positioned over the button corresponding to the folder), a pane 50 (illustrated in FIG. 5) is created in which the administrator can control the list of the instances managed by the interface (that is, those displayed in the box 15). The user can add, modify, or delete an instance from the list.
The pane 50 includes a title bar 51, a first field 52 indicating or making it possible to indicate in a text editing box the name of a node (Node), a second field 53 indicating or making it possible indicate in a text editing box the name of an instance (Instance) attached to the node indicated in the field 52, a third field 54 indicating or making it possible to indicate in a text editing box the path of this instance (environment value Oracle -- Home), a fourth field 55 indicating or making it possible to indicate in a text editing box the SQL communication string (SQL Index String) which makes it possible to connect to the instance from another node (a STRING is an Oracle data type: a string ending in a null value), if this possibility is available in the network, a fifth field 56 indicating or making it possible to indicate in a text editing box the name of the UNIX administrator (Administrative UNIX User) for this instance, a sixth field 57 indicating or making it possible to indicate in a text editing box the name of the ORACLE administrator (Administrative oracle User) for this instance, a seventh field 58 indicating or making it possible to indicate in a text editing box the password (Password) of the ORACLE administrator to whom the instance belongs, a box 59 with a vertical scroll bar which presents and allows the selection of the instances having been entered by the administrator (for example by displaying, for each instance, a line indicating the node in which they are running, their name, their ORACLE path and their associated SQL index string), a first control button 501 (ADD) which makes it possible to validate an addition of an instance, a second control button 502 (DELETE) which makes it possible to delete one of the instances present in the box 59, a third control button 503 (MODIFY) which makes it possible to modify the values related to one of the instances present in the box 59, and a fourth control button 504 (QUIT) which makes it possible to leave the pane 50.
In order to add an instance to the list of instances managed by the interface, the administrator will fill in the fields 52 through 58 with the information corresponding to this instance, and select the button "ADD". It is possible to provide for a series of checks to be carried out in order to ensure that the input data is valid, for example by initiating an access to the node indicated in the field 52 by performing a check of the access rights for executing remote commands of the shell type (shell is a command language in the UNIX world) (if the rights are not defined, the user can be given the ability to define them by means of an xterm session (a known session of the X/Motif interface) under the name of the user entered; the user must then modify the file $HOME/.rhosts (a UNIX world file) during the xterm session by adding a line with the name of the node in which ORACLE is running and the name of the user under whose name it is running, and finally to check the access to the instance under the name and the password entered. If the connection has not been made, the corresponding ORACLE error is returned. In the opposite case, a new line is inserted in the box 59. Simultaneously, an icon 1523 is created in the box 15.
To delete or modify an instance indicated in the box 59, the line corresponding to this instance is selected, for example by clicking twice on the left button of the mouse, the mouse pointer being positioned over the line. The fields 52 through 59 then display the information related to the instance selected. If the "DELETE" button is selected, the line is deleted in the box 59. If the "MODIFY" button is selected, the values can be modified in the same way they were created.
The pane 50 is exited by selecting the "QUIT" button.
By selecting the Processes folder 121, a pane 60 (illustrated in FIG. 6) is created in which the administrator has access to a view of the current state of the processes related to a given instance of a given node. The selection of the object Processes must be preceded by the selection of an instance appearing in the box 15.
The pane 60 includes a title bar 61, a first field 62 indicating the name of a node (Node), a second field 63 indicating the name of an instance (Instance), a third field 64 indicating the current time references (Time, for example the current day, date and time), a box 65 with vertical and horizontal scroll bars which presents information on the processes related to the instance (for example by displaying a square 650 for each process which includes a first field 651 indicating the name of the process), a second field 652 indicating the name of the user (User) to whom the process belongs, a third field 653 indicating the size (Size) of the process in page frames, and a fourth field 654 indicating the accumulated execution time of the process in the central processor (CPU) in minutes and seconds, and a control button 601 (QUIT) which makes it possible to leave the pane 60.
It is particularly important to know the accumulated execution time of a process, which makes it possible to detect whether a process has been running too long, that is, whether it is monopolizing the resources of the machine on which it is running to the detriment of the other processes.
By selecting the Events folder 122 by means of the mouse, a pane 70 (illustrated in FIG. 7) is created in which the administrator has access to a state of the most recent events (Events) and to a list of the log files (Logfiles) related to the events, for a given instance and a given node. The selection of the object Events must be preceded by the selection of an instance appearing in the box 15.
The pane 70 includes a title bar 71, a first box 72 with horizontal and vertical scroll bars presenting information on the most recent events related to the instance (for example by displaying one line per event which indicates the application involved, the time references of the event, the name of the node involved, a message related to the event--for example an error message if the event involves an abnormal operation--the name of the instance in question, and the references of the trace file related to the event), a second box 73 with horizontal and vertical scroll bars presenting information on the trace files related to the events (for example by displaying one line per trace file indicating the path of the file, the rights relative to the file, the size of the file), a first control button 701 (VIEW) which makes it possible to edit contents the of the files in a xterm session by means of the mouse, and a second control button 702 (QUIT) which makes it possible to leave the pane 70.
Access to the contents of the trace files is gained, for example by opening an xterm session, by clicking twice on the left button of the mouse, the mouse pointer being positioned over the line of the box 73 describing the file, or by selecting this line by clicking on this button and selecting the "VIEW" button.
By selecting the Configuration folder 123, a pane 80 (illustrated in FIG. 8) is created in which the administrator has access to a list of parameters related to an instance. The selection of the object Configuration must be preceded by the selection of an instance appearing in the box 15.
The pane 80 includes a title bar 81, a box 82 with horizontal and vertical scroll bars presenting a list of fields related to parameters of the instance (for example identification parameters, characteristic parameters, parameters specific to the operating systems or to the network), and a control button 83 (QUIT) which makes it possible to leave the pane 80.
A set of parameters associated with the ORACLE instance will be displayed, and the user can choose these parameters from among those provided by the ORACLE SQL request called "Showparameters".
By selecting the Files folder 124, a pane 90 (illustrated in FIG. 9) is created in which the administrator has access to the names and locations of files related to the instances, and to their contents if they are text files. The selection of the object Files must be preceded by the selection of an instance appearing in the box 15.
The pane 90 includes a title bar 91, a first box 92 with horizontal and vertical scroll bars presenting information on the configuration files (configfiles) related to the instance, a second box 93 with horizontal and vertical scroll bars presenting information on the control files (controlfiles) related to the instance, a third box 94 with horizontal and vertical scroll bars presenting information on the data files (datafiles) related to the instance, a first control button 901 (VIEW) which makes it possible to access the contents of a text file, and a second control button 902 (QUIT) which makes it possible to leave the pane 90 by means of the mouse.
The information related to a file will be displayed, for example in the form of a line indicating the name (Name) of the file, the physical location (Location) of the file, the rights (Rights) attached to the file, the reference of the owner (Owner) of the file, the reference of the proprietary group (Group) to which the file belongs, the size (Size) of the file in octets, the time data (Month, Day, Time) corresponding to the last modification or the creation of the file, and for the data files, the logical name (Tsame) in the ORACLE domain.
A configuration file could be edited by positioning the mouse pointer over the line corresponding to this file and clicking twice on the left button of the mouse, or by selecting it (by clicking once on the left button of the mouse after positioning the pointer over the line) and selecting the "VIEW" button.
By selecting the Scripts folder 125, a pane 100 (illustrated in FIG. 10) is created in which the administrator has access to a set of scripts.
The pane 100 includes a title bar 101, a first box 102 with horizontal and vertical scroll bars presenting information related to a list of scripts, a second box 103 with horizontal and vertical scroll bars presenting information related to the execution of a script, a first control button 104 (ADD) which makes it possible to add an existing script to the list of scripts, a second control button 105 (NEW) which makes it possible to create a new script, a third control button 106 (DELETE) which makes it possible to delete a script from the list of scripts, a fourth control button 107 (EXECUTE) which makes it possible to start the execution of a script, a fifth control button 108 (SHELL) which makes it possible to open an xterm session, and a sixth control button 109 (QUIT) which makes it possible to leave the pane 100.
Each script (or executable file) is described by a line which gives its name (Name) (this will be, for example, its access path or a name related to the current Oracle directory), its type (Type), that is the type of language (SHELL or SQL) to which it refers, which depends on the type of system referred to, the number of parameters (Nbpars) to be defined in order to allow its execution, and a possible description (Description) of the script.
By selecting the "ADD" button, a pane 110 (illustrated in FIG. 11) is created by means of which the administrator can add an existing script to the list of scripts managed by the interface.
The pane 110 includes a title bar 111, a first field 112 which makes it possible to indicate in a text editing box the name of the script, a second field 113 which makes it possible to indicate in a text editing box the type of the script, a third field 114 which makes it possible to indicate in a text editing box the number of parameters to be defined in order to start the script, a fourth box 115 which makes it possible to indicate in a text editing box a possible description of the script, a first control button 116 (OK) which makes it possible to confirm, by selecting it with the aid of the mouse, the insertion of the script into the list, and a second control button 117 (CANCEL) which makes it possible, by selecting it with the aid of the mouse, to leave the pane 110 and to cancel the information appearing in it.
By selecting the "NEW" button, it is possible to create a script and add it to the list. An xterm session is opened and a vi session (a session which allows the display of a file to be viewed in a text editor under UNIX) is initiated. The user can then enter the text of the script. Once he has saved the file, a pane identical to that which appears in the case where a script is added is displayed in order to allow the insertion of the new script into the list managed by the interface.
By selecting the "DELETE" button, after having selected a script in the box 102 (for example by clicking once on the left button of the mouse when it is positioned over the line of the script), a pane 130 (illustrated in FIG. 12) is created in which the administrator can choose between the removal of the script from the list and the possible deletion of the script.
The pane 130 includes a title bar 131, a field 132 indicating the name of the script, a first control button 133 (LIST ONLY) which makes it possible to confirm, by selecting it, the removal of the script from the list of managed scripts (the file still exists), a second control button 134 (FILE AND LIST) which makes it possible to confirm, by selecting it, the deletion of the script itself and of its presence in the list of managed scripts, and a third control button 135 (CANCEL) which makes it possible, by selecting it, to leave the pane 130 and to cancel the operation in progress.
By selecting the "EXECUTE" button after having selected both a script in the box 102 (for example by clicking once on the left button of the mouse when it is positioned over the line of the script) and an instance in the box 15, a pane 140 (illustrated in FIG. 13) is created in which the administrator indicates the parameterization values necessary to the execution of the script, if the script requires the knowledge of parameters.
The pane 140 includes a title bar 141 and a certain number of fields corresponding to the number of parameters to be defined in order to allow the execution of the scripts. In the example illustrated in FIG. 13, the pane 140 includes five fields 142 through 146, each of which makes it possible to indicate in a text editing box the value of a parameter.
The pane 140 also includes a first control button 147 (OK) which makes it possible, by selecting it, to validate the choice of the parameter values indicated and to start the execution (the pane 140 is then closed), and a second control button 148 (CANCEL) which makes it possible, by selecting it, to leave the pane 140 and to cancel the information appearing in it.
The box 103 allows the user to have access to the contents of the error and output files resulting from the execution of a script, which are displayed in this box.
By selecting the Errors folder 126, a pane 160 (illustrated in FIG. 14) is created in which the administrator has access to the available information in the base related to the error code.
The pane 160 includes a title bar 161, a first field 162 indicating or making it possible to indicate in a text editing box the group identification code of an ORACLE error, a second field 163 indicating or making it possible to indicate in a text editing box the number of an Oracle error, a third field 164 indicating the text corresponding to the literal associated with an error, a fourth field 165 indicating the text corresponding to the cause associated with an error, a fifth field 166 indicating the text corresponding to the action to be taken in order to correct the error, a sixth field 167 indicating the text corresponding to the comments associated with an error, a seventh field 168 indicating the text corresponding to the document to be consulted regarding an error, a first control button 1601 (OK) which makes it possible to validate, by selecting it, a search for information related to an error once the group identification code and the number have been entered in the fields 162 and 163, and a second control button 1602 (QUIT) which makes it possible, by selecting it, to leave the pane 160.
The window 160 allows the user to determine the significance of an ORACLE error code. The interrogation is done by indicating the group of the error and its number in the fields 162 and 163. A literal, a cause, an action, comments and a document are received in return (with ORACLE, this information is supplied in a file in which they may be searched for, for example by means of a dichotomizing search).
While this invention has been described in conjunction with specific embodiments thereof, it is evident that many alternatives, modifications and variations will be apparent to those skilled in the art. Accordingly, the preferred embodiments of the invention as set forth herein, are intended to be illustrative, not limiting. Various changes may be made without departing from the spirit and scope of the invention as set forth herein and defined in the claims. | An administrator interface working with a relational data base management system belonging to a distributed data processing environment including a plurality of folders which reflect the states of the network and objects in the network, relative to the management (120), the processes (121) in the course of running, the events (122) which affect the processes (121), the configuration (123), the files (124), the command scripts (125), and the errors (126), and a software program for allowing access to and/or manipulation of the folders. | 7 |
BACKGROUND OF THE INVENTION
(1) Field of the Invention
The present invention relates to an improved sound rated floor system and a method for constructing same, and more particularly to a novel structure for a sound rated floor comprising an attenuation layer having acoustically semi-transparent first and second facings bonded to a core and a rigid layer positioned above the attenuation layer. Also disclosed is a method for constructing a sound rated floor using such an attenuation layer.
(2) Description of the Prior Art
Sound rated or floating floor systems are known in the prior art for acoustically isolating a room beneath a floor on which impacts may occur, such as pedestrian footfalls, sports activities, dropping of toys, or scraping of furniture being moved.
Impact noise generation can generally be reduced by using thick carpeting, but where concrete, tile, or hardwood finishes are to be used a sound rated floor may be particularly desirable. The transmission of impact noise to the area below can be reduced by resiliently supporting the floor away from the floor substructure, which typically transmits the noise into the area below. If the floor surface receiving the impact is isolated from the substructure, then the impact sound transmission will be greatly reduced. Likewise, if the ceiling below is isolated from the substructure, the impact sound will be restricted from traveling into the area below.
Sound rated floors are typically evaluated by ASTM Standards E90 or #336 and #492 and are rated as to impact insulation class (IIC). The greater the IIC rating, the less impact noise will be transmitted to the area below. Floors may also be rated as to Sound Transmission Class (STC). The greater the STC rating, the less airborne sound will be transmitted to the area below. Sound rated floors typically are specified to have an IIC rating of not less than 50 and an STC rating of not less than 50. Even though an IIC rating of 50 meets many building codes, experience has shown that in luxury condominium applications even floor-ceiling systems having an IIC of 56-57 may not be acceptable because some impact noise is still audible.
In addition to having an adequate STC and IIC rating, an acceptable sound rated floor must also have a relatively low profile. Low profile is important in order to maintain minimum transition height between a finished sound rated floor and adjacent areas, such as carpeted floors, which ordinarily do not need the sound rated construction.
Also, a sound rated floor must exhibit enough vertical stiffness to reduce cracking, creaking, and deflection of the finished covering. At the same time, the sound rated floor must be resilient enough to isolate the impact noise from the area to be protected below.
Two isolation media currently used and also approved by the Ceramic Tile Institute for sound rated tile floors are (i) 0.4 inch Enkasonic matting (nylon and carbon black spinerette extruded 630 g/sq. meter) and (ii) 0.25 inch Dow Ethafoam (polyethylene foam 2.7 pcf). While both of these systems are statically relatively soft and provide some degree of resiliency for impact insulation, the added effect of air stiffness in the 0.25 and 0.40 inch thick media makes the system very stiff dynamically and limits the amount of impact insulation. Because the systems are statically soft, they do not provide a high degree of support for the finished floor, and a relatively thick (7/16 inch) glass mesh mortar board, such as a product called Wonderboard, is used on top of the media to provide rigidity for preventing grout, tiles, and other finished flooring from cracking. Alternatively, a relatively thick (11/4 inch) reinforced mortar bed must be installed on top of the resilient mat.
SUMMARY OF THE INVENTION
In accordance with the present invention, a sound rated floor for resting on a subflooring and supporting a finished covering is provided, said sound rated floor comprising a sound attenuation layer having a core and at least one acoustically semi-transparent first facing bonded to the core and a rigid layer positioned on the sound attenuation layer for supporting the finished flooring.
Also provided are moisture inhibiting layers for positioning between the subflooring and the sound attenuation layer, or between the sound attenuation layer and the rigid layer for inhibiting the passage of moisture therethrough.
In a particularly preferred embodiment, the attenuation layer comprises a paper honeycomb core having cells open to a first and second side thereof, and first and second facings of fiberglass are bonded to the first and second sides of the core, respectively. Such an attenuation layer is manufactured and sold as a composite panel structure by Peabody Noise Control, Inc., Dublin, Ohio. The rigid layer comprises glass reinforced concrete boards, a reinforced mortar bed, or wood surface such as plywood.
The Peabody composite panel structure preferred for the present invention has a nominal thickness of 5/8 inch. The high compressive strength and static stiffness of this panel structure permits use of a thinner (1/4 inch thick) glass reinforced concrete (GRC) board such as Sterling Board by Cem-Fil Corporation, Flex-board by Johns-Manville Co., and Ultra-Board Regular by Brit-Am Venture Marketing Limited to provide rigidity and to provide minimum elevation transition from floating to non-floating floor areas.
It is an object of the present invention to provide a sound rated floor system that adequately supports the finishing covering while effectively attenuating incident impact noise.
It is a further object of the present invention to provide a sound rated floor system having a reduced elevation transition.
A further object of the present invention is to provide a sound rated floor having an attenuation layer which is relatively stiff to imposed static loads to prevent cracking of overlying grout and tile, but which is relatively soft when exposed to dynamic or impact loads to dissipate impact noise within the structure of the attenuation layer.
It is a further object of the present invention to provide a method for constructing a sound rated floor system.
Additional advantages of the sound rated floor system of the present invention and method for making same will be apparent from the brief description of the drawings and the detailed description of the preferred embodiment below.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a cross-sectional view of a first embodiment of a sound rated floor system constructed in accordance with the present invention;
FIG. 2 is a cross-sectional view of a second embodiment of a sound rated floor system constructed in accordance with the present invention;
FIG. 3 is a cross-sectional view of a third embodiment of a sound rated floor constructed in accordance with the present invention;
FIG. 4 is a cross-sectional view of a fourth embodiment of a sound rated floor constructed in accordance with the present invention; and
FIG. 5 is a cross-sectional view of a fifth embodiment of a sound rated floor constructed in accordance with the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
FIG. 1 discloses a preferred embodiment of the sound rated floor system of the present invention. In FIG. 1, a base substructure or subflooring 100 is fixed to cross members or joists 102, which provide rigid support for the subflooring 100. The subflooring 100 should be structurally sound, with deflection not exceeding 1/360 of the span, including live and dead loads. In the present embodiment, the subflooring comprises 2 or 3 layers of plywood nailed or glued to the joists 102. A ceiling 104 (optional) may be affixed to the bottom side of the joists 102 by means of resilient clips 106. Thermal/acoustical insulation means 103 may be placed above the ceiling 104 and below the subflooring 100 and also between the joists 102.
The attenuation layer 110 is placed or adhered above and directly on top of the subflooring. In the preferred embodiment, the attenuation layer 110 provides the acoustic isolation feature of the sound rated floor of the present invention.
The structure of the attenuation layer 110 is described fully in U.S. Pat. No. 4,522,284 to Fearon et al. and is manufactured as a composite panel structure by Peabody Noise Control, Inc., Dublin, Ohio. Acoustical panel 110 preferably includes a first facing 120 of semi-resilient material, preferably a fibrous material such as fiberglass with a higher density or hardened outer surface with lower density pillow-like portions extending into the cellular cores. The facing 120 is bonded directly to a cellular core 122, which is preferably a walled structure such as a honeycomb formed of cardboard, kraft paper, aluminum or similar material. In a particularly preferred embodiment, expandable hexagonal cells having walls 124 of kraft paper comprise the cellular core 122. A second facing 126 of semi-resilient material similar to the first facing 120 is bonded directly to the cellular core 122 to form the other side of acoustical panel 110.
The facings 120 and 126 are essentially planar along their outer surfaces 128 but extend inward as convex pillows 130 so as to partially fill the cells of the core 122. The facings 120 and 126, initially formed as an uncured blanket of relatively uniform thickness and density, are formed during the manufacture of the acoustical panel 110 into a quilt-like configuration. The facings 120 and 126 form valleys or channels 132 for receiving the walls 124 and corresponding thin portions 134 between the walls 124 and the outer surfaces 128. Less dense, acoustically semi-transparent portions 136 remain between the channels 132, and soft inner surfaces 138 extend into the cells formed by the walls 124.
The attenuation layer provides control of both airborne noise to provide a high degree of sound transmission loss and structure-borne noise to provide a high degree of impact noise insulation, such as caused by pedestrian footfall.
The core thickness and spacing of the walls 124 may be varied to permit tuning of the acoustical structure to a particular absorption frequency range. Generally, an increase in the volume of the cells results in a lower tuned absorption frequency. As a result of the combined sound absorption of the facings 120 and 126 and the entrapped air spaces 140 of the core 122, the acoustical panel 110 exhibits better sound absorption over a broader frequency range than homogeneous fiberglass of a comparable thickness. Furthermore, the acoustical panel 110 exhibits better sound absorption than a corresponding honeycomb core layup having fiberglass facings of relatively uniform thickness bonded to the core by conventional methods.
The unique construction of the Peabody composite panel structure preferred here as the attenuation layer results in a system which is relatively stiff to imposed static loads to prevent cracking of the overlying grout and tile but which is relatively soft when exposed to dynamic or impact loads due to the venting of the increased air pressure caused by the impact through the valving effect of the fiberglass into the cores of the honeycomb.
The preferred attenuation layer for use in the present invention has a perpendicular distance from the relatively hard outer surface of the first facing to the relatively hard outer surface of the second surface of the second facing of equal to or less than approximately 5/8 inch, with the diameter of the cells being equal to or less than approximately 1/2 inch. Also, other forms of composite panel structure, such as those described in U.S. Pat. No. 4,522,284, can be used in the sound rated floor of the present invention. For example, an attenuation layer having a septum in the center of the core or a panel having a first facing, an interlayer interposed between a core, and a second facing could also be used as well for greater thickness depending upon construction requirements.
After the attenuation layer, the next layer in the preferred embodiment may be an optional moisture inhibiting layer 112, preferably a membrane placed directly on and above the attenuation layer.
The next layer, which is placed directly on top of the moisture inhibiting layer or membrane 112, is a rigid layer 114 for supporting the finished covering to avoid cracking. This rigid layer 114 preferably comprises glass reinforced concrete boards, such as the concrete glass fiber reinforced construction panel manufactured by Modulars, Inc. of Hamilton, Ohio and sold under the trademark "Wonderboard". Wonderboard is available in a thickness of 7/16 inch at a weight of approximately 3.5 pounds per square foot. A similar cement board is marketed under the trademark "Flexboard" by the Johns-Manville Company. In addition, another concrete panel is marketed under the trademark "Ultra-board Regular" by Brit-Am Venture Marketing Limited of Middlesex, N.J. This is an inorganic cementitious board available in thicknesses from 3/16 inch to 1/2 inch and in panel sizes of 8 and 10 feet by 4 feet in width.
The next layer, placed directly on top of the glass reinforced concrete boards, is a grout or thin set adhesive layer 116. The finished covering 118, such as ceramic tile, is then placed on top of the grout layer 116.
In an alternative embodiment, where the finished covering is to be a hardwood finish or vinyl tile instead of a ceramic tile finish, the rigid layer 114 may be constructed by two or three layers of plywood substituted for the glass reinforced concrete boards. The hardwood finished covering is then bonded or nailed to the plywood to complete the sound rated floor system.
Another preferred embodiment, similar in many respects to FIG. 1, is shown in FIG. 2. In FIG. 2, a base surface or subflooring 142 comprises precast concrete or poured concrete over an appropriate supporting or floor joist structure 144, which can also support an optional ceiling 146 below on resilient clips 148. An acoustical panel 150 similar to the panel 110 described above with respect to FIG. 1 is placed directly on top of the concrete subflooring 142. An optional moisture inhibiting layer 152, such as a membrane, is then placed on top of panel 150. A rigid layer 154 is next, such as glass reinforced concrete boards, followed by an adhesive layer 156 and the finished flooring 158.
FIG. 3 shows yet a third embodiment of the present invention. Subflooring 160 comprising three layers of plywood is secured to joists indicated as 162. Gypsum board, ASTM C36 Type and 5/8 inch thick, forms ceiling 166 held on by resilient clips 167, and insulation material 164 is laid between the subflooring 160 and ceiling 166. The Peabody composite panel structure 168 is placed above subflooring 160, and a reinforced mortar bed 170 is laid down next. A bond coat 172 comprising dry-set mortar or latex portland cement mortar is placed next, on top of which is the finished covering of ceramic tile 174. An elastomeric or acoustical sealant 176 can be placed around the perimeter.
FIG. 4 presents yet a fourth alternative embodiment substantially like that shown in FIG. 3, except primarily that a concrete subflooring 178 is used.
FIG. 5 presents yet a fifth alternative embodiment. In this embodiment, joists 186 support wooden sleepers 182 and a gypsum board or plaster ceiling 180 below. A plywood or other wooden subfloor 188 is on top, with fiberglass bats 184 in between subflooring 188 and sleepers 182. The Peabody 5/8 inch thick molded fiberglass honeycomb composite forms the sound attenuation layer 190, upon which is placed two layers 192 and 194 of plywood, the second layer 194 being cross lapped. The finished covering 196, such as hardwood, vinyl tile, or other hard floor finish then goes on top.
Use of the acoustic panel disclosed herein as the noise attenuation layer or isolation medium provides better performance than the isolation mediums of the prior art with respect to the important characteristics of noise attenuation, rigidity, and thickness. The ideal isolation medium would provide good noise attenuation with sufficient rigidity to support a tile floor without cracking, while at the same time would have minimal thickness to provide for a minimum transition between the floor and adjacent carpeted areas. Before the acoustic panel of this invention was used as an isolation medium, the prior art taught that a relatively soft isolation medium was necessary to inhibit the transmission of noise through the isolation medium. However softness or lack of rigidity in the isolation medium caused difficulties in maintaining a sufficiently rigid surface for the finished cover to avoid cracking problems. To increase rigidity and attenuation required an undesirable increase in thickness.
The acoustical panel of the present invention is rigid enough at relatively small thicknesses to provide adequate support for the finished covering, but at the same time imparts better noise attenuation properties to a sound rated floor than does the prior art material.
It should be understood that various changes and modifications to the preferred embodiment described above will be apparent to those skilled in the art. Such changes and modifications can be made without departing from the spirit and scope of the present invention, and it is therefore intended that such changes and modifications be covered by the following claims. | A sound rated flooring is provided comprising a sound attenuation layer having a composite panel structure having a core and at least one acoustically semi-transparent facing of fibrous material bonded to the core and a rigid layer positioned on the sound attenuation layer. A moisture inhibiting barrier may be positioned between the composite panel structure and the rigid layer. A method for constructing a sound rated floor is also provided, comprising the steps of positioning the composite panel structure described herein over a substantially horizontal base surface and then positioning the rigid layer over the composite panel structure. The finished covering is then placed over the rigid layer. | 4 |
RELATED APPLICATIONS
This application is a continuation of U.S. Ser. No. 08/175,939 filed Dec. 30, 1993, now abandoned, which is a continuation of U.S. Ser. No. 07/842,012 filed on Feb. 26, 1992, now abandoned, which is a continuation-in-part of U.S. Ser. No. 07/795,695, filed Sep. 9, 1991, now U.S. Pat. No. 5,181,276, which is a continuation of U.S. Ser. No. 07/484,137, filed Feb. 22, 1990, now abandoned.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to infection resistant polyurethanes. More particularly, the invention relates to the incorporation of viricidal agents into a thermoplastic polyurethane matrix. These infection resistant polyurethanes can be used to make gloves, condoms and other items.
2. Description of the Prior Art
It is known that, for manufacturing devices from a molten blend of polymer, it is suitable to add same additives such as plasticizer(s) and antioxidant(s). It is also known to cover devices with a layer containing an antibacterial agent. For covering such devices, a composition containing a polymer, a solvent of said polymer and an antibacterial agent is prepared, said composition being then applied on the surface of the device so that, after drying, the device is provided with an antibacterial polymeric layer. Such devices are expensive and have antibacterial properties only on one surface thereof.
It is known to add to molten polyvinyl chloride benzoate of sodium or mercury salts for avoiding a microbial growth on said polymer; however, such additives are toxic for the health so that the use thereof has to be proscribed.
NONOXYNOL-9 (α-(nonylphenyl-w-hydroxypoly (oxy-1-2,ethanediyl), a nonionic surfactant has been described as an inhibitor of the growth of herpes simplex virus and HTLV-III. NONOXYNOL-9 (α-(nonylphenyl-w-hydroxypoly(oxy-1-2, ethanediyl), has also been used in spermicides. See Fox, U.S. Pat. No. 4,581,028.
SUMMARY OF THE INVENTION
This invention provides thermoplastic infection resistant polyurethane made by the process comprising: mixing a nonionic surfactant having a Hydrophilic Lipophilic Balance of between 12 and 20, the said compound consisting of:
R.sub.1 --O--((CH.sub.2)a.sub.i --O) n-R.sub.2
where R 1 is a saturated or unsaturated hydrocarbon radical, a i is, for i=to n, an integer greater or equal to 2; R 2 is an organic radical, the constituent elements selected from the group consisting of carbon, hydrogen or oxygen, n is an integer selected so that the Hydrophilic Lipophilic Balance of said compound is between 12 and 20, said compound comprising at least 1% of thermoplastic polyurethane by weight, and a sufficient amount of an organic solvent to obtain a one phase solution and, combining this solution with thermoplastic polyurethane. Additionally, a plasticizer can be mixed with the nonionic surfactant.
The molten blend of this invention may thus, for example, be: extruded, injected or dip moulded so as to manufacture infection-resistant materials or devices; or sprayed on materials or devices so as to provide said materials or devices with a infection-resistant layer.
The invention also relates to infection resistant devices for example surgical gloves, surgical clothes, surgical operative fields, finger stalls, aprons, bibs, caps, condoms, etc, manufacturers for example by injecting into a mould a molten blend of a polymer mixed with the compound. The invention relates to composition of polymer(s) containing the compound, the compounds or/and compositions being suitable for the manufacture of viral infection-resistant devices according to the invention.
BRIEF DESCRIPTION OF THE FIGURES
FIG. 1 shows thickness (μm) versus sample type.
FIG. 2 shows percent elongation versus sample type.
FIG. 3 shows tensile at breaks (N/mm 2 ) versus sample type.
FIG. 4 shows modules (N/mm 2 ) versus sample type.
FIG. 5 shows a calibration curve for nonionic surfactant.
DETAILED DESCRIPTION OF THE INVENTION
Nonionic surfactants are compounds of the general formula:
R.sub.1 --O--((CH.sub.2)a.sub.i --O).sub.n -R.sub.2 (1)
where
R 1 is a saturated or unsaturated hydrocarbon group;
a i is, for i=1 to n, an integer greater or equal to 2;
R 2 is an organic group possibly substituted, and
n is an integer selected so that the Hydrophile-Lipophile Balance of said compound is comprised between 12 and 20.
Since the compounds of formula in which R 1 , R 2 , a i and n have the above given meanings does not affect the polymer network properties, such as tensile strength, elasticity modules, etc up to 10% or even more of said compounds may be added.
Compounds of general formula:
R.sub.1 --O--((CH.sub.2)a.sub.i --O).sub.n -R.sub.2
are known as being nonionic surfactants. These compounds may be characterized by a Hydrophile-Lipophile Balance as taught by GRIFFIN, W. C., J. Soc. Cosmet. Chem.1, 311-326 (1949). Such compounds are, for example, alkylphenoxypoly (ethyleneoxy) ethanol and more specifically ANTAROX (nonylphenoxypoly (ethyleneoxy) ethanol) ANTAROX 630 (nonylphenoxypoly(ethyleneoxy) ethanol), and NONOXYNOL-9 (α-(nonylphenyl-w-hydroxypoly (oxy-1-2, ethanediyl)). Methods for the manufacturing of such compounds are given for example, in U.S. Pat. Nos. 1,970,578 and 2,774,709.
It has been found that these compounds have viricidal action against Hepatitis B, C HIV-I and II, Chlamydia trachomatis, Neisseria gonorhoerea, Trichomonas vaginalis, Candida albicans, Treponema pallidium, and Herpes Simplex I & II. The compounds are stable at temperature of about 200° C.
Certain plasticizers can also be used to increase the incorporation of nonionic surfactant into a polymer and also to work as viscosity regulators of the solution. To act as a plasticizer, within the scope of this invention the plasticizer must have a molecular weight of at least 300. It should have a similar solubility parameter to that of the polymer. The solubility parameters can be determined by Small's method. Small, Relation of Structure to Chemical Properties, J. Appl. Chem., 3:71 (1953). If the polymer has any tendency to crystallize it should be capable of some specific interaction with the polymer. It should not be crystalline solid at ambient temperature unless it is capable of specific interaction with the polymer. For example, from Table 5.6, of Small it can be seen that plasticizers for polyvinyl chloride such as the octyl phthalates, triolyl phosphate and dioctyl sebacate have solubility parameters within the 1 c.g.s unit of that the polymer.
On the other hand, dimethyl phthalate and the paraffinic oils which are not polyvinyl chloride plasticizers fall outside the range.
Most common acids used are:
ACETIC ACID
CITRIC ACID
ACONITIC ACID
TARTRIC ACID
ADIPIC ACID
SEBACIC ACID
TRIMELLITIC ACID
PHTHALIC ACID, etc.
The chain length of the alcohol molecules involved in the chemical reaction with a particular type of acid will give a compound which has to meet the requirements to act as a plasticizer.
Practically, phthalates prepared from alcohols with about eight carbon atoms are by far the most important class and probably constitute about 75% of the plasticizers used, more known as DEHP (Di ethyl Hexyl phthalate).
In the glove formulation, we use the di-iso nonyl phthalate (DINP), which formula is described here under. ##STR1##
The thermoplastic polyurethane useful in this invention can be divided into categories: esters and ethers. More particularly, DESMOPAN KA 8500 (Bayer Co.) and DESMOPAN KU2-8600 (Bayer Co.) have been found to be useful. The selection of the thermoplastic polyurethane depends on the ultimate application of the material such as for a glove or condom.
In a method according to the invention, a nonionic surfactant and the plasticizer are solubilized in an organic solvent prior to adding to a polyurethane. When manufacturing for example disposable gloves, the compound of general formula will be distributed between the surface and the polymer matrix. For example, the plasticizer Di Iso Nonylphthalate and the nonionic surfactant NONOXYNOL-9 (α-(nonylphenyl-w-hydroxypoly (oxy-1-2,ethanediyl) are added to polyurethane pellets with the organic solvent such as tetrahydrofuran. Di Iso Nonylphtha-late and NONOXYNOL-9 (α-(nonylphenyl-w-hydroxypoly (oxy-1-2,ethanediyl) are weighed in a glass beaker and then solubilized into a volume of solvent before being added to the polymer. The example section shows various amounts of nonionic surfactant and plasticizer in volumes of solvent. The specific amount selected is determined experimentally based on the surfactant, plasticizer and solvent selected and the end use of the infection resistant thermoplastic polyurethane.
Organic solvents that are useful in this invention include: tetrahydrofuran and 1,4 Dioxane. In general, any solvent with solubilization parameters close to those of the polymer will work. It should be noted, however, that solvents such as methyl ethyl ketone and ethyl acetate produce a swelling of the material without reaching complete solubilization. In these instances a combination of solvents may be an alternative to solve incomplete solubilization of the solvent with the polymer. The components are mixed to obtain a one phase solution of polyurethane and organic solvent.
Therefore, the infection-resistant devices according to the invention provide an viricidal properties including: contact protection and a protection mechanism in case of pinholes or microcracks.
Thus, in the case of a polymer based product the polymer network works as a reservoir for the nonionic surfactant, releasing on demand, an effective concentration of nonionic surfactant on both sides of the polymer film. This process provides two benefits: 1) by releasing nonionic detergent to the outside of the polymer film, surfactant that may have been removed by surface contact is replaced. Second, as surfactant is released to the inside, protection is provided from the many pinholes that developed in a thin polyurethane film.
EXAMPLE 1
Materials and Methods
Material:
Polyurethane RX 366: DESMOPAN KA 8550 (Bayer Co.) and RX 367: DESMOPAN KU2-8600 (Bayer Co.).
Methods:
Preparation of Solution
1) RX 366
Solution obtained by mixing 40 g of DESMOPAN KA 8550 (Bayer Co.) with 450 ml of tetrahydrofuran (8.9% weight/volume).
2) RX 366+10% NONOXYNOL-9 (α-(nonylphenyl-w-hydroxypoly (oxy-1-2,ethanediyl)
Same as for RX 366 but four g of NONOXYNOL-9 (α-(nonylphenyl-w-hydroxypoly (oxy-1-2,ethanediyl) are added to the polyurethane pellets before mixing with the 450 ml tetrahydrofuran. The 10% of NONOXYNOL-9 (α-(nonylphenyl-w-hydroxypoly (oxy-1-2,ethanediyl) is based on weight of thermoplastic polyurethane
3) RX 366+10% Di-Iso Nonylphtalate
Same as for RX 366 but four g of Di-Isononylphtalate are added to the polyurethane pellets before mixing with 450 ml tetrahydrofuran.
4) RX 366+10% NONOXYNOL-9 (α-(nonylphenyl-w-hydroxypoly (oxy-1-2,ethanediyl)+5% Di-Isononylphtalate
Same as for RX 366 but four g of NONOXYNOL-9 (α-(nonylphenyl-w-hydroxypoly (oxy-1-2,ethanediyl) and four g of Di-Isononylphtalate are added to the polyurethane pellets before mixing with 450 ml tetrahydrofuran.
5) RX 366+10% NONOXYNOL-9 (α-(nonylphenyl-w-hydroxypoly (oxy-1-2,ethanediyl)+10% di-iso nonylphtalate
Same as for RX 366 by four g of NONOXYNOL-9 (α-(nonylphenyl-w-hydroxypoly (oxy-1-2,ethanediyl) and four g of di-iso nonylphtalate are added to the polyurethane pellets before mixing with 450 ml tetrahydrofuran.
6) RX 367+10% NONOXYNOL-9 (α-(nonylphenyl-w-hydroxypoly (oxy-1-2,ethanediyl)+5% Di-Iso Nonylphtalate
Solution obtained by mixing forty g of DESMOPAN (Bayer Co.) KY2-8600 with four g NONOXYNOL-9 (α-(nonylphenyl-w-hydroxypoly (oxy-1-2,ethanediyl) and two g di-iso nonylphtalate before adding to 450 tetrahydrofuran.
Preparation of Films
The polymer solution is poured into a mold. The excess of material is removed using a mobile knife mounted on a support. The knife height is adjusted using micrometric screws. The coated molds were vaccum dried in an oven for one minute, powdered and stripped. Alternatively, any means used to remove excess organic solvent may be employed.
Mechanical Testing:
Technical conditions are summarized as follows:
The specimen were prepared according to ASTM D638M type M-II. Elongation, tensile at break and modulus are calculated on the graph obtained by the graph obtained by following certain dedicated test conditions:
grip separation: 25.4 mm (for thin sheating)
crosshead speed: 20% (200 mm/min)
load cell: 5N
extension ratio i/10 mm: BE (strain conversion factor where 1 volt equals a strain of 49.2 mm).
These test can be conducted on standard material testing equipment such as a Zwick, and are routine for one skilled in the art of materials.
Thickness measurements are made based on ASTM D374, method C.
TABLE 1______________________________________ THICK- NESS TENSILE ELONGATION MODULUSSAMPLE (μM) (N/mm.sup.2) (%) (N/mm.sup.2)______________________________________PVC glove 160 + -30 11 + -1.7 290 + -47 7.9 + -0.69Viricidal 160 + -16 12 + -0.58 350 + -16 7.2 + -0.41PVC gloveRX366 140 + -34 36 + -3.3 570 + -37 8.6 + -1.2RX366 + 120 + -33 31 + -6.0 730 + -140 7.4 + -1.7N9 (10%)RX366 + 160 + -26 37 + -4.7 640 + -46 7.6 + -0.98DINP (10%)RX366 + 150 + -19 29 + -1.2 750 + -90 5.7 + -0.45N9 (10%) +DINP (5%)RX367 + 100 + -13 29 + -4.4 550 + -130 6.6 + -0.66N9 (10%) +DINP (5%)______________________________________
EXAMPLE II
Each of the films prepared in Example 1 where tested for chemical extraction of nonionic surfactant. The method (Greff et Al: Determination of Nonionics. Journal of the American Oil Chemists' Society, Vol. 42 (1965), 180) is based on the formation of a blue complex between ammonium cobaltothiocyanate reagent and a polyethoxylated compound. The complex is extracted into benzene from a saturated salt solution and measured with a spectrophotometer at 320 μm. The absorbance reading is compared to a standard.
Materials and Reagents
Reagent
Ammonium thiocyanate
Cobalt nitrate hexahydrate
620 g of reagent grade ammonium thiocyanate and 280 g of reagent grade cobalt nitrate hexahydrate was dissolved in water and dilute to 1 liter. The reagent was extracted twice with benzene to obtain a blank reading.
Procedure
100 ml of sample solution was placed into a separatory funnel. 15 ml of ammonium cobaltothiocyanate reagent was added to 35-40 g of sodium chloride. The mixture was shaken to dissolve the salt and allowed to stand for 15 minutes. 25 ml of benzene was added to the funnel. The mixture was shaken for one minute, and then let stand to separate the layers. The lower aqueous layer was discarded and the organic layer was transfered to a centrifuge tube and spun for ten minutes. Using a spectrophotometer, the peak absorbance at 320 μm was read after scanning the region between 200 and 500μ against a reagent blank. The absorbance reading obtained on a sample was compared with a standard of know concentration.
The data shown in FIG. 5 were obtained by testing various Antarox CO-630 (nonylphenoxypoly (ethyleneoxy) ethanol). The series was constituted of four samples containing respectively 2.1, 4.2, 6.3 and 10.5 mg of Antarox CO-630 (nonylphenoxypoly (ethyleneoxy) ethanol). The curve obtained is characterized by a correlation coefficient of 0.994.
Table 2 summarizes the data regarding the NONOXYNOL-9 (α-(nonylphenyl-w-hydroxypoly (oxy-1-2,ethanediyl) (α-(nonylphenyl-w-hydroxypoly (oxy-1-2,ethanediyl) extraction from the thermoplastic polyurethane film made in Example 1.
TABLE 2______________________________________POLYURETHANE FILM N9 CONCENTRATION (*)______________________________________Film 1RX366 + DINP (10%) 0 mgRX366 + DINP (10%) 0 mgFilm 2RX366 + N9 (10%) 11.34 mgRX366 + N9 (10%) 10.53 mgFilm 3RX366 + N9 (10%) + DINP (5%) 11.88 mgRX366 + N9 (10%) + DINP (5%) 11.52 mg______________________________________ * Results obtained from the extraction of 108 square cm. of each film in 900 ml of water for 30 min.
This data shows that for film 2 NONOXYNOL-9 (α-(nonylphenyl-w-hydroxypoly (oxy-1-2,ethanediyl) is present in the films. The results performed on the third type of film show that in the presence of 5% Di Iso Nonylphthalate, the amount of extracted NONOXYNOL-9 (α-(nonylphenyl-w-hydroxypoly (oxy-1-2,ethanediyl) is the same.
EXAMPLE III
Mechanical Properties
Samples A and B are gloves made of polyvinyl chloride. Samples C, D, E, F and G are polyurethane films of varying thickness.
TABLE 3
Analysis of Thermopolyurethanes
Sample Type
A: Polyvinylchloride (glove)
B: Polyvinylchloride containing 10% NONOXYNOL-9
C: Desmopan KA8550 (Bayer Co.) (polyurethane)
D: Desmopan KA8550 (Bayer Co.) containing 10% NONOXYNOL-9
E: Desmopan KA8550 (Bayer Co.) containing 10% DINP
F: Desmopan KA8550 (Bayer Co.) containing 10% NONOXYNOL-9 and 5% DINP
G: Desmopan KU2-8600 (Bayer Co.) containing 10% NONOXYNOL-9 and 5% DINP
Sample A: Polyvinylchloride made of plastisol as described page 12 of U.S. Ser. No. 484,137; Sample B: Polyvinylchloride containing 10% NONOXYNOL-9 (α-(nonylphenyl-w-hydroxypoly (oxy-1-2, ethanediyl); Sample C: RX366 DESMOPAN KA8550 (Bayer Co.); Sample D: RX366 containing 10% NONOXYNOL-9 (α-(nonylphenyl-w-hydroxypoly (oxy-1-2, ethanediyl);
Sample E: RX366 containing 10% Di Iso Nonylphthalate;
Sample F: RX366 containing 10% NONOXYNOL-9 (α-(nonylphenyl-w-hydroxypoly (oxy-1-2,ethanediyl) and 5% Di Iso Nonylphthalate;
Sample G: RX367 DESMOPAN KU2-8600 (Bayer Co.) containing 10% NONOXYNOL-9 (α-(nonylphenyl-w-hydroxypoly (oxy-1-2,ethanediyl) and 5% Di Iso Nonylphthalate.
Thickness
When the viscosity of the polymer solution containing NONOXYNOL-9 (α-(nonylphenyl-w-hydroxypoly (oxy-1-2,ethanediyl) is lowered, the thickness of the polyurethane film is decreased. In fact, NONOXYNOL-9 (α-(nonylphenyl-w-hydroxypoly (oxy-1-2,ethanediyl) added to the polymer solution decreases the viscosity which induces a decrease of the film thickness. (FIG. 1. Sample type D) This is observed by comparing respectively D and C as well as F and E. G is another sample made of another type of polyurethane. See FIG. 1.
Elongation and Modulus
NONOXYNOL-9 (α-(nonylphenyl-w-hydroxypoly (oxy-1-2,ethanediyl), incorporated into the thermoplastic polyurethane, increases the elongation and decreased the modulus. See FIGS. 2 and 4.
As expected, the plasticizing effect of the NONOXYNOL-9 (α-(nonylphenyl-w-hydroxypoly (oxy-1-2,ethanediyl) slightly decreases the modulus but increases the elongation property. The incorporation of 5% di-iso nonylphtalate into the DESMOPAN KA 8550 (Bayer Co.) containing 10% NONOXYNOL-9 (α-(nonylphenyl-w-hydroxypoly (oxy-1-2,ethanediyl) allows to control the viscosity of the polymer solution. Tensile at break, elongation and modulus are in the same range than the 10% NONOXYNOL-9 (α-(nonylphenyl-w-hydroxypoly (oxy-1-2,ethanediyl) formulation. Films made of Rx366 with 10% NONOXYNOL-9 (α-(nonylphenyl-w-hydroxypoly (oxy-1-2,ethanediyl) and 10% di-iso nonylphtalate had elongation values out of the range of the test system.
Tensile at break
A concentration of 10% NONOXYNOL-9 (α-(nonylphenyl-w-hydroxypoly (oxy-1-2,ethanediyl) in DESMOPAN KA 8550 (Bayer Co.) slightly decreases the tensile at break of the thermoplastic polyurethane. Here two polyvinyl chloride samples are differentiated from the polyurethane samples which have "tensile at break" value three times higher. Samples D and F have "tensile at break" values decreasing slightling when compared to sample C. Sample E value is comparable to sample C. See FIG. 3.
Although the invention has been described primarily in connection with special and preferred embodiments, it will be understood that it is capable of modification without departing from the scope of the invention. The following claims are intended to cover all variations, uses, or adaptations of the invention, following, in general, the principles thereof and including such departures from the present disclosure as come within known or customary practice in the field to which the invention pertains, or as are obvious to persons skilled in the field. | The present invention relates to infection resistant polyurethane having the infection resistant agents incorporated into the matrix of the thermoplastic polyurethane resin. This agent acts as a pool of infection resistant material. This infection resistant material can be used to make gloves and condoms. | 2 |
DESCRIPTION
This application is a continuation-in-part of copending application Ser. No. 07/541,894, filed Jun. 21, 1990.
TECHNICAL FIELD
The present invention relates to corner beads for drywall construction, and particularly to those having an outer paper layer.
BACKGROUND OF THE INVENTION
In the corner bead for drywall construction art two types of beads have been commonly used, the "nail-on" type and the "tape-on" type. Nail-on beads commonly take the form of an angle strip of metal with side flanges meeting at a center corner rib providing shoulders against which spackle or joint cement can be dressed when feathered from the adjoining wall surfaces to cover the edges and outer faces of the side flanges and the heads of the nails securing these flanges to the wall structure. These nails are usually driven through the bead flanges at intervals of no more than eight inches.
Another form of nail-on bead has a rounded nose section between side flanges and presents step-down shoulders at the junctures of the rounded nose and the side flanges. The nails are driven through the side flanges and the spackle or joint cement covering the flanges is dressed to the shoulders, leaving the rounded nose section exposed to be painted later. For purposes of later discussion, corner beads with an abrupt corner will be referred to as the "hard-line" type, and the corner beads with a rounded nose will be referred to as the "soft-line" type.
Tape-on corner beads utilize paper wings to secure a metal corner angle in position rather than using nails. These wings are lateral extensions of a paper cover strip which is bonded by a hot melt glue or other suitable adhesive to the metal corner angle, usually on the outer faces of the side flanges. The metal corner angle can be shaped as the hard-line type or soft-line type. Spackle or joint cement and wall paint for dressing and finishing the corner, normally adhere significantly better to the paper cover strip of tape-on beads than to the exposed metal of nail-on beads. Also, normally drywall corners covered with nail-on heads are more susceptible to developing crack lines along the outer edges of the side flanges than when tape-on beads are used. On the other hand, nail-on beads have the advantage of requiring less skill to apply.
Preparatory to painting the wall board adjoining a corner covered by a corner bead, the spackle or joint cement spread from the wall surface onto the corner bead is sanded to provide a smooth continuous surface from the wall board to the corner bead. In the case of tape-on beads the exposed portion of the outer paper layer is commonly scuffed during the sanding operation, thereby making it more difficult to later obtain a smooth painted surface at the corner. This scuffing is usually most pronounced at the corner rib of a hard-lien bead, and at the two shoulders adjoining the rounded nose of a soft-line bead.
SUMMARY OF THE INVENTION
The present invention provides an improved nail-on corner bead having advantages of tape-on beads and which can be produced economically. The invention also provides a solution to the scuffing problem of tape-on beads.
In accordance with the present invention, a metal corner element (hard-line or soft-line) is covered on the outside with a paper layer which is folded around the outer edges of the corner element and is bonded to the corner element. The back side of the metal corner element is preferably provided with a reinforcing layer of paper between the folded-around portions of the front paper layer. This permits the metal corner element to be of thinner material. The overall cost of the thinner metal and reinforcing backing paper provides a structure currently more economical to produce than when metal alone is used of a thickness normally currently found (0.012-0.013 inches) on all-metal nail-on corner beads. The corner element has a pair of shoulders as currently provided on hard-line and soft-line types, respectively, of nail-on beads. The portion of the paper layer covering and adjoining each shoulder is provided with a protective coating making it far more resistant to scuffing during the sanding operation in preparation for painting. The protective coating has a composition to which paint will readily adhere. As part of the invention this protective coating is also applied to the pater cover layer of tape-on corner beads.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a transverse cross-sectional view of a hard-line corner bead made in accordance with the present invention, and with the thickness of the elements being exaggerated for illustrative purposes;
FIG. 2 is a detail sectional view to an enlarged scale of the circled portion indicated in FIG. 1;
FIG. 3 is a transverse cross-sectional view of a soft-line corner bead made in accordance with the present invention, and with the thickness of the elements being exaggerated for illustrative purposes;
FIG. 4 is a detail sectional view to an enlarged scale of the circled portion indicated in FIG. 3; and
FIGS. 5 and 6 are fragmentary transverse cross-sectional views of a hard-line corner bead and soft-line corner bead, respectively, of the tape-on type provided with the protective coating in accordance with this invention.
DETAILED DESCRIPTION OF THE INVENTION
Referring to the drawings, it is seen that finished hard-line and soft-line nail-on corner beads 8, 9 made in accordance with the present invention have a respective core strip 10, 11 and a respective paper cover strip 12 or 13. The core strip is preferably a galvanized steel strip which has been roll-formed to the hard-line shape 10 having a corner rib 10a and side flanges 10b, or to the soft-line shape 11 having a rounded nose 11a, a pair of step-down sloped shoulders 11b, and side flanges 11c. A typical hard-line core strip 10 will have its side flanges 10b at ninety degrees to one another and about one inch wide, and a typical soft-line core strip 11 will have its rounded nose 11a shaped with a radius in the range of about 3/4 to 11/2 inches, and its side flanges 11c at a right angle relative to one another and about one inch wide. The corner rib 10a on the hard-line unit will typically be about 0.0625 inches high and about 0.125 inches wide. Each of the shoulders 11b on the soft-line unit will typically be about 0.125 inches wide and have a drop of about 0.0625 inches from the corresponding outer edge of the rounded nose section 11a and the adjoining side flange 11c.
The cover strips 12, 13 have their outer edge portions 12a and 13a folded back over the outer edges of the respective core strips 10, 11 a distance of about 0.25 inches. For economy of construction, respective reinforcing backing strips 14, 15 of paper may be applied to the core strips 10, 11 between the folded-back edge portions 12a, 13a of the respective cover strips 12, 13. The cover strips 12, 13 may be 80 to 90 pound bleached kraft paper like that commonly used for wallboard joint tape, and the backing strips 14, 15 may be kraft paper about 0.016 to 0.017 inches thick like that commonly used for backing paper on wallboard. When the backing strips 14, 15 are not used, the core strips 10, 11 will normally be about 0.012 to 0.013 inches thick, whereas the core strips need only be about 0.007 to 0.009 inches thick when the backing strips are included. Hot melt glue or other suitable adhesive (not shown) is used to bond the entire back surface of the cover strips 12, 13 and backing strips 14, 15 to the core strips 10, 11.
In accordance with the present invention a center band 16 of a protective coating is applied to the outer face of the cover strip 12, and a pair of bands 17 of a protective coating is applied to the portions of the outer face of the cover strip 13 which cover the pair of shoulders 11b and are adjacent thereto. The protective bands 16, 17 preferably extend about 0.125 inches beyond both side edges of the corner rib 10b and the shoulders 11b. Although for production economy it is preferred to have relatively narrow protective bands, it will be appreciated that in the case of the soft-line bead 9 a protective band may extend over the entire width of the nose 11a between the pair of shoulders 11b.
FIGS. 5 and 6 show the protective bands 16 and 17 applied to standard tape-on beads 8' and 9' with hard-line and soft-line configurations in which the paper cover layers are numbered 12' and 13', and the metal core strips are identified by 10' and 11', respectively. The portions of the core strips are identified in the same manner as in FIGS. 2 and 3, except that a prime has been added.
The bands 16, 17 of protective coating preferably result from treatment of the outer paper layers 12, 13 (12', 13') with a material which penetrates the fibers of the paper to reinforce the paper and provide surface protection against abrasion. For example, the coating material for the bands 14 15 may comprise a fine particle size, acrylic, water-based emulsion such, for example, as Synthemul® synthetic resin emulsion 40-423, produced by Reichhold Chemicals, Inc., Dover, Del., diluted 50% with water. This material may be applied by a brush, roller or spraying apparatus. When the coating has dried, the surface of the paper area to which the coating material has been applied will normally have an acrylic film or layer about 0.001 inches in thickness. This surface film or layer can be increased in thickness to about 0.005 inches by using a suitable primer sealer for the protective coating. For example, the same acrylic resin can be utilized with the following additional ingredients:
______________________________________INGREDIENT % (BY WEIGHT)______________________________________Water 8.00Ethylene Glycol 1.00Cellulosic thickness solution 16.00Potassium Tripolyphosphate 0.10Defoamer 0.40Surfactant 0.40Aluminum Silicate 12.00Titanium Dioxide 7.50Calcium Carbonate 15.00Microbial Agent 0.10Acrylic Resin 39.50______________________________________
A typical cellulosic thickener is Natrosol 250 HR solution (11/2%).
In applying the hard-liner and soft-line embodiments of the nail-on beads 8-9, nails are driven at regular intervals through the outer cover strips 12, 13 underlying flanges 10b, 11c of the core strips, and backing strips 14, 15, and then spackle or joint cement is feathered from the outer face of the underlying wallboard to the rib 10a and shoulders 11b so as to cover the outer edges of the corner beads and the nails, as indicated in phantom in FIGS. 2 and 4. Since the outer edges of each core strip 10, 11 and the outer faces thereof are covered with paper there is good adherence of the spackle or joint cement to the corner beads. When the spackle or joint cement is later sanded the protective bands 16, 17 prevent adverse scuffing of the paper 12 covering the corner rib 10a and the paper 13 covering the rounded nose 11a adjacent the shoulders 11b. Covering of the relatively sharp outer edges of the metal core strips 10, 11 with the paper covering 12, 13 has the added advantage of protecting workers from hand cuts while handles the corner beads.
The hard-line and soft-line corner beads 8'-9' of the tape-on type are applied in the conventional manner for tape-on beads. When the joint cement covering the outer paper layer 12' from the corner rib 10'a to the outer edge of the paper 12' on the hard-line tape-on bead 8', and covering the outer paper layer 13' from the rounded nose 11'a to the outer edge of the paper 13' on the soft-line tape-on bead 9', is sanded to dress the joint cement to the rib 10'a and nose 11'a, the protective bands 16', 17' prevent adverse scuffing of the outer paper layers 12', 13'.
It will be appreciated that the thickness of the protective coatings 16, 17 have been somewhat exaggerated in the drawings for illustrative purposes. The portions of the outer paper layer in FIGS. 2, 4, 5 and 6 adjoining the protective coatings 16, 17 have been dotted to indicate impregnation of the paper by the coating material. | A corner bead for drywall construction has a galvanized steel core strip which is formed with a central portion, side flanges, and shoulders joining the central portion and side flanges. The front face of the core strip is covered with a paper layer having an outer protective coating thereon overlying the central portion adjoining said shoulders. A paper reinforcing layer covers the back of the core strip in one embodiment to minimize the thickness of the core strip. | 4 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims priority under 35 U.S.C. § 119(e) on U.S. Provisional Application No. 60/727,881, entitled SOFT X-RAY GENERATOR, filed on Oct. 18, 2005, by Robert (NMI) Dotten, et al., the entire disclosure of which is incorporated herein by reference.
BACKGROUND OF THE INVENTION
[0002] The present invention relates to improvements in a soft x-ray generator. U.S. Pat. No. 6,240,163 discloses a soft x-ray (also referred to as EUV) electromagnetic radiation source which provides improved short bursts of radiation in the about 75 ev to about 12 Kev range. These bursts of radiation have a maximum intensity for use in a variety of applications, including lithography, crystallography, and radiography, in the scientific, industrial, and medical fields.
[0003] The disclosure of U.S. Pat. No. 6,240,163 is incorporated herein by reference. Although the system disclosed in the '163 patent represents a vast improvement over prior art soft x-ray generators, there remains a need for a system which has a longer useful life under continuous high frequency operating conditions by preventing, for example, erosion of the anode as well as having a more predictable and reliable trigger operation for initiating the discharge between the anode and cathode for such continuous operation.
SUMMARY OF THE INVENTION
[0004] The soft x-ray generator of the present invention satisfies these needs and provides additional benefits by including a unique pulse trigger assembly which reliably and reproducibly provides a plasma and initiates the discharge between a cathode and an anode. The trigger assembly has a cone-shaped geometry which implements gas discharge to provide efficient and reliable operation of the trigger. In one embodiment, the soft x-ray generator of the present invention includes a rotating anode which is generally disk-shaped with an outer circumferential edge which is rotated with respect to the cathode to expose different sections of the anode to the vacuum spark discharge, which produces the plasma, thereby reducing anode wear and providing longer term operation. Anode erosion is also reduced by liquid cooling of the anode. The generator of this invention utilizes a relatively low capacitance for the cathode-to-anode discharge and a relatively high pulse repetition rate (frequency) to achieve its continuous reproducible results.
[0005] These and other features, objects and advantages of the present invention will become apparent upon reading the following description thereof together with reference to the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0006] FIG. 1 is a schematic view of a soft x-ray generator embodying the present invention;
[0007] FIG. 2 is a perspective view, partly in phantom, of the soft x-ray generator housing and its components contained within the vacuum chamber shown in FIG. 1 ;
[0008] FIG. 3 is a right elevational view of the x-ray generator shown in FIG. 2 ;
[0009] FIG. 4 is a front elevational view of the x-ray generator shown in FIGS. 2 and 3 ;
[0010] FIG. 5 is a cross-sectional view of the anode and trigger assembly shown in FIGS. 2 and 4 ;
[0011] FIG. 6 is an exploded perspective view of the trigger assembly shown in FIG. 5 ;
[0012] FIG. 7 is an enlarged cross-sectional view of the assembled trigger assembly shown in FIG. 5 ;
[0013] FIG. 7A is a front view of the cathode;
[0014] FIG. 8 is a perspective view of the anode assembly, the motor assembly, and the trigger assembly removed from the chamber;
[0015] FIG. 9 is a front elevational view of the anode and trigger assemblies;
[0016] FIG. 10 is a rear elevational view of the cathode assembly;
[0017] FIG. 11 is an exploded perspective view of the rotating anode assembly shown in FIGS. 1, 2 , 5 , and 8 ;
[0018] FIG. 12 is a perspective view of the anode shown in FIG. 4 ;
[0019] FIG. 13 is a front elevational view of the rotating anode shown in FIG. 12 ;
[0020] FIG. 14 is a cross-sectional view, taken along section lines XIV-XIV of FIG. 13 , of the rotating anode shown in FIGS. 1, 2 , and 13 ;
[0021] FIG. 15 is an exploded view of the drive and cooling system for the anode;
[0022] FIG. 16 is a vertical cross-sectional view of the assembled structure of FIG. 15 ; and
[0023] FIG. 17 is an electrical circuit diagram, in schematic form, of a high voltage power supply used with the soft x-ray generator of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0024] It should be understood that the invention is not limited to the details of the particular arrangement shown and described since the invention is capable of other embodiments. Materials and the parameters used herein are for the purpose of description not of limitation. Referring initially to FIG. 1 , there is shown an x-ray generator 10 of the present invention, which includes an outer chamber 12 through which various power supplies, cooling conduits, a gas supply conduit 27 , and a vacuum pump are sealably coupled in a conventional manner to supply operating voltage, an inert gas to the trigger electrode assembly via conduit 27 , different cooling fluids to both the trigger assembly and rotating anode, as well as a vacuum for the interior 11 of the sealed chamber 12 . The x-ray generator comprises in the preferred embodiment a trigger electrode assembly 100 and a rotating anode assembly 200 , which are shown in detail in the various drawing figures of this application. Both of these assemblies are contained within the vacuum chamber interior 11 , and one or more capacitor(s) 20 is/are coupled between the anode assembly 200 and trigger assembly 100 including cathode 106 . The capacitor 20 is charged by a pulsed power source 22 at from about −3 kv to about −20 kv, depending upon the desired operation characteristics. Power source 22 is shown and described in FIG. 17 . The capacitor is charged/discharged at a repetition rate which corresponds to the frequency of trigger operation of from about 1 Hz to about 100 kHz. The trigger electrode 100 is coupled to a trigger power source 24 , which provides pulses at the same frequency with a voltage amplitude of from about −3.5 kv to about −30.0 kv.
[0025] The overall geometry of the x-ray generator 10 and the chamber 12 housing the component parts is shown in FIGS. 2-4 . Chamber 12 comprises a generally cylindrical body 14 having an annular flange 18 at one end which includes a sealing O-ring 17 for sealing the open end when engaged by a hinged circular door 26 . In order to sealably clamp the door 26 in a closed, vacuum-tight seal with the chamber 12 , a locking clamp assembly 29 of conventional design and including a rotary locking knob, as seen in FIGS. 3 and 4 , is employed. Door 26 is hinged to flange 18 by a hinge 28 and includes a sealed window 30 so the interior 11 of the chamber can be viewed, either through the door 26 or through a viewing port comprising a flange 32 extending from a conduit 34 from body 14 . The viewing port may include a pin diode 36 for observing the pulse discharge between the cathode and anode of the x-ray generator.
[0026] Generator 10 also includes an exit port 40 (best seen in FIG. 3 ) which includes a window 19 where an x-ray filter can be installed. When a beryllium window 19 is employed, it typically has a thickness of from about 3 to about 20 microns, and preferably of from about 8 to about 10 microns, and is fairly transparent to the soft x-rays generated in chamber 11 . The soft x-rays generated by the generator 10 pass through the window and can be applied to a device employing such x-rays through a mounting flange 42 . Such devices may include instruments used for lithography, crystallography, radiography, and other scientific or medical appliances which benefit from the soft x-rays generated by generator 10 .
[0027] Flange 42 and port 40 are also coupled to the cylindrical body 14 of chamber 12 through a cylindrical conduit which communicates with the cathode assembly as described below. Body 14 of chamber 12 is mounted by mounting brackets 38 and 39 , which are coupled to cylindrical body 14 and are mounted to a base 44 which is supported by a suitable cabinet which accommodates the remainder of the components, including the power supplies, control circuit, and fluid and liquid supplies and pumps for the generator 10 .
[0028] A relatively large cylindrical conduit 46 communicates with the interior space 11 of chamber 12 and is coupled to a high vacuum pump for evacuating the interior 11 of the chamber to achieve a vacuum of from about 10 −4 to about 10 −6 torr. Conduit 46 terminates in a flange 47 for coupling to the high vacuum pump (not shown).
[0029] Sealably coupled to the rear wall 13 ( FIG. 3 ) of housing body 14 by means of a flange 50 is a motor assembly 300 . Assembly 300 includes a vacuum bearing 360 in housing 310 ( FIGS. 15 and 16 ), a motor housing 320 , and a rotary cooling water supplying housing 330 described in greater detail below. Motor assembly 300 rotates a rotary drive shaft 312 coupled to the rotating anode 200 as well as provides cooling fluid, such as water, thereto. The components of the chamber 12 are suitably machined from stainless steel.
[0030] The trigger assembly 100 is shown in detail in FIGS. 5-7 and is mounted in insulated relationship to chamber body 14 within space 11 ( FIG. 2 ) and adjacent rotating anode assembly 200 in the relationship also seen in FIGS. 4, 5 , and 8 . Between the rotating anode 200 and the cathode 106 of trigger assembly 100 , there is mounted one or more capacitors 20 between spaced-apart mounting plates 21 and 23 for providing a capacitance of from about 1 nano-farad to about 1 micro-farad depending upon the desired operational characteristics of the system. Capacitor 20 comprises a pair of generally disk-shaped capacitors 20 a and 20 b coupled in parallel ( FIGS. 9, 10 and 17 ).
[0031] Trigger assembly 100 includes a generally annular trigger electrode 120 , which concentrically surrounds cone-shaped member 102 having a tip 103 engaging cathode 106 , as best seen in FIG. 7 . Electrode 120 and cone-shaped member 102 define a cone-shaped gas-filled chamber 129 , as best seen in FIGS. 5 and 7 . Nozzle 106 also includes a cone-shaped exit aperture 107 . The negative voltage from source 24 ( FIG. 1 ) is applied between the trigger electrode 120 and cone 102 and causes the ionization of the inert gas within the trigger chamber 129 between them and produces a plasma and free electrons. The gas typically can be an inert gas, such as argon or the like, or other kinds of gases, e.g. nitrogen or mixtures supplied to chamber 129 . When the gas discharge occurs in the chamber, the free electrons and the plasma diffuse through the holes 60 ( FIGS. 7 and 7 A) and the open tip 107 of the cathode nozzle 106 into the gap between the cathode and anode toward the grounded anode assembly 200 . The electrons are accelerated by the electric field provided by the applied high voltage between the cathode and anode from the pulsed power source 22 . When the electrons impinge upon the anode, an anode plasma is generated of the copper anode material (although other anode materials can be employed), which diffuses toward the cathode. Upon the meeting of both plasmas, the discharge of capacitor(s) 20 between the grounded anode and negative high voltage cathode is initiated. During the discharge process, electric current increases rapidly in nano seconds and, due to the current pinching effect, a plasma region of small size is formed between the cathode and anode where the plasma is increasing in temperature, and the copper ions and atoms in the plasma are multiple ionized. This results in the generation of soft x-rays of point source size which exit through exit port or window 105 ( FIGS. 5 and 7 ) of the trigger electrode assembly 100 into chamber 12 . Chamber 12 may include several radiation transparent windows, such as window 19 , to allow the soft x-rays generated between the cathode and rotating anode to be externally focused and employed for a variety of applications.
[0032] The relationship of the trigger assembly 100 to the anode assembly 200 is seen in FIGS. 5 and 8 , with the cathode structure also shown in FIG. 2 , being mounted within the chamber 12 by, in part, a phenolic insulator plate 16 which includes apertures 15 for mounting the cathode assembly in insulative relationship to rear wall 13 of chamber body 14 . A pair of brackets 33 and 35 ( FIG. 8 ) extend from insulator 16 and clamp the trigger housing 110 in place. Conductive plate 23 ( FIGS. 8-10 ) is coupled to capacitors 20 a , 20 b and is secured to the housing 110 of trigger assembly 100 , as seen in FIG. 8 . As described below, the remaining conductive plate 21 is coupled to the opposite side of capacitors 20 a , 20 b and a conductive end bearing 228 of the rotary anode assembly 200 . Having briefly described the main components of the system and its operation, a detailed description of the geometry of the trigger assembly, and, subsequently, the rotating anode assembly is now provided in connection with FIGS. 5-7 .
[0033] The trigger assembly is best seen in FIGS. 5-7 and includes a fluid (such as oil) cooled trigger housing 10 which includes an annular, finned oil-cooling channel 126 formed therein surrounding and facing the trigger electrode 120 . The cooling channel is supplied with cooling fluid, such as oil, through an inlet 111 and an outlet 112 which provides a flow path through the sealed housing for the admission of cooling oil, which is cooled externally of chamber 11 . An oil inlet hose (not shown) supplies cooled oil to inlet 111 of housing 110 while an oil outlet hose (not shown) returns the heated oil from outlet 112 through a sealed coupling in the chamber conduit 46 to be cooled externally.
[0034] A trigger housing rear cover 116 is sealably mounted to trigger housing 110 by means of fasteners 119 and a sealing O-ring 114 . Cover 116 includes an inert gas inlet 118 for the admission of an inert gas into the interior of chamber 129 defined by the sealed assembly. The negative voltage applied to the trigger electrode 120 is applied through a conductor 117 in insulator 123 . Conductor 117 extends through trigger housing 110 ( FIG. 7 ) and is coupled to the ring-shaped trigger electrode 120 . The trigger voltage is applied through ( FIG. 7 ) which is extended to the ring-shaped trigger electrode 120 for applying a relative pulsed negative voltage between cathode 106 and electrode 120 of from about −0.5 kv to about −10 kv.
[0035] Trigger electrode 120 is insulated from the housing 110 by a rear insulator 122 , a front insulator 124 , and insulator 123 , all of which are mounted in sealable engagement within the trigger chamber 104 by a series of O-rings 130 , 132 , and 134 . An O-ring 115 sealably couples the trigger front cover 128 to the trigger housing 110 and is held in place by suitable fasteners, such as fasteners 136 ( FIGS. 6 and 7 ). The cathode trigger nozzle 106 (forming the cathode) is secured to the trigger front cover 128 by means of a nozzle retaining disk 108 and suitable fastening screws 109 secured within threaded apertures in the front mounting plate 128 . A slight gap “g” of from about 0.010 inch to about 150 inch exists between the cone 102 and trigger electrode 120 . When the high voltage is applied via conductor 117 between trigger electrode 120 and cone 102 , a plasma is formed within chamber 129 , which communicates with the vacuum chamber 11 through one or more radially spaced apertures 60 in the cathode, as best seen in FIG. 7A . The apertures 60 , as also shown in FIG. 7 , communicate between chamber 129 and the opening 107 of the cathode nozzle 106 , which includes an annular mounting flange 64 , as seen in FIG. 7A , to facilitate its mounting, as shown in FIG. 7 , to the front mounting plate 128 . In one preferred embodiment of the invention, the apertures 60 were equally spaced at 120° intervals and had a diameter of approximately 0.030 inch with a nozzle opening 107 having an inner diameter of 0.040 inch. In some applications, a greater or fewer number of equally spaced apertures 60 may be provided to feed the plasma contained within conical chamber 129 to the exit aperture 107 of cathode 106 . When the plasma is formed within the chamber 129 of trigger electrode assembly 100 , therefore, the plasma is drawn by the negative pressure in chamber 11 outwardly through aperture 107 toward the rotating anode assembly 200 and to the edge 204 ( FIGS. 5 and 8 ) of the anode 202 (described below) with spacing “s” ( FIG. 5 ) from about 1 mm to about 6 mm between the tip of cathode 106 and the aligned edge 204 of anode 202 .
[0036] A perspective view of the assembled trigger assembly 100 is shown in FIG. 8 , which illustrates the mounting of the capacitors 20 a and 20 b with one mounting plate 23 being secured by fasteners 127 ( FIG. 9 ) to the edge of trigger front cover 128 and the remaining mounting plate 21 supporting the rotating anode assembly 200 through a conductive bearing as described below.
[0037] The trigger assembly includes a second cone 102 spaced from the conical interior walls 121 ( FIG. 7 ) of the oil-cooled rear housing 116 and main housing 110 . Cone 102 also remains relatively hot and is not affected by the oil-cooled housing and further prevents debris from clogging the aperture in cone 102 adjacent cathode 106 . The beryllium window 19 typically has a thickness of from about 3 to about 20 microns and preferably of from about 8 to about 10 microns and is fairly transparent to the soft x-rays generated in chamber 11 . The window 105 is held in place on the open aperture of rear housing 116 by an annular mounting ring 125 which is held in place by threaded fasteners 101 . Having described the trigger assembly, a description of the rotating anode assembly is now provided in connection with FIGS. 5, 8 , and 10 - 16 . Rotating anode assembly 200 comprises a generally circular disk-shaped anode 202 made of copper or other suitable metal, which, as best seen in FIG. 14 , has an outer peripheral edge 204 formed at the flattened tip of the intersecting, converging walls 206 and 208 of the body of anode 202 . Anode 202 includes a concave depression 210 defined by a peripheral rim 215 on one side and a similar concave depression 212 defined by peripheral rim 219 on the opposite side separated by a central disk-shaped wall 211 . Anode 202 is sealably held between a cup-shaped first end wall 220 and a second cup-shaped end wall 230 , which extend within rims 219 , 215 ( FIG. 16 ), respectively, and are sealed thereto by means of O-rings 222 and 232 , respectively. End wall 230 includes a threaded aperture 240 for receiving the threaded end 311 ( FIG. 15 ) of hollow drive shaft 312 . Cooling fluid, such as water, is introduced as described below through a supply conduit 332 concentric within hollow drive shaft 312 and can flow within the chamber defined by cavities 210 , 212 between members 220 and 230 through central opening or aperture 213 in wall 211 . For such cooling, a plurality of spaced-apart apertures 214 ( FIGS. 11-14 ) are formed at angles which follow and are parallel to the converging walls 206 , 208 and are spaced inwardly therefrom. The apertures 214 have an inner diameter of about 0.113 inch and their location therefor provides a flow path for coolant immediately adjacent edge 204 . the apertures 214 extend around the peripheral edge of wall 211 of anode 202 and extend toward the edge 204 to promote the flow of the water from cavity 212 under pressure through aperture 213 through apertures 214 into cavity 210 to maintain the anode at an operating temperature well below what normally would be encountered. The walls 206 , 208 converge at about 45° forming an angle of about 90° at edge 204 . The thickness of the generally triangular peripheral edge where walls 206 , 208 join the body 211 is about 0.5 inch. The anode is positioned, as best seen in FIGS. 5 and 8 , with the edge 204 being spaced, as noted above, from about 1 mm to about 6 mm from the tip of cathode trigger nozzle 106 , such that the plasma drawn through aperture 107 bombards the highly charged edge 204 of the anode to form the metallic ions, which subsequently gather to form a pinch zone, and the generation of soft x-rays, as discussed above. In one embodiment, anode 202 had an outer diameter of about 4.9 inches, although other diameter anodes may be employed.
[0038] End walls 220 , 230 of the sealed hollow anode assembly 200 are attached to the anode 202 , which includes three equally spaced recessed apertures 216 for receiving cap screws which thread into three equally spaced threaded apertures 217 ( FIG. 16 ) on the inner surface of end wall 230 to attach the anode to wall 230 . The anode, in turn, includes three equally spaced interspersed threaded apertures 218 which receive hex bolts 223 ( FIGS. 9 and 16 ) for attaching end wall 220 to anode 202 in sealed engagement therewith. End wall 220 includes a blind mounting boss 224 which is internally threaded to receive the threaded axle end 226 ( FIG. 16 ) of a conductive bearing 228 which is mounted to plate 21 . Bearing 228 includes an internally threaded stub axle 229 which receives and is secured to plate 21 by means of a threaded nut 233 . Thus, the axle 226 is allowed to rotate with respect to the fixed body 228 and stub axle 229 of the conductive bearing, as also illustrated in FIG. 8 . Having described the anode assembly 200 and its rotatable mounting at one end to the stationary grounded plate 21 , a description of the rotating drive shaft 312 and its mounting to body 14 of the outer chamber 12 of x-ray generator 10 is now described in connection with FIGS. 15 and 16 .
[0039] The drive system for the rotary drive shaft 312 coupled to the rotating anode assembly 200 is now described in connection with FIGS. 15 and 16 . The assembly 300 is employed for not only rotating the anode 202 at a speed of up to about 1500 rpm but also to supply a cooling fluid, such as water, to the anode 202 through the hollow drive shaft 312 . The supply of fluid can be tap water and the return drained, or, in some applications, a loop of coolant can be employed and the heated coolant returned to a chiller for recirculation. This is accomplished by the structure shown in FIGS. 15 and 16 , which includes the hollow drive shaft 312 having a central, longitudinally extending aperture 314 for receiving in spaced concentric relationship the cooling fluid supply tube 332 . Shaft 312 includes a threaded end 313 for receiving a rotatable fitting 336 of a water supply union 331 as shown in FIG. 16 . The drive shaft 312 also is splined along the area 315 to center the motor rotor 322 , which includes a stater 324 . Rotor 322 is mounted between bearings 321 and 323 and affixed to shaft 312 in area 315 with epoxy within recess 333 of housing 310 at one end and to recess 334 in motor housing section 320 . Drive shaft 312 also includes circumferential snap-ring apertures 317 for receiving snap rings for securing bearings 321 and 323 in longitudinal alignment with shaft 312 . The diameter of shaft 312 increases toward end 311 as it extends through a ferrule fluidic bearing, which is commercially available, for example, from Ferrotec Corporation Model No. HS- 1500 -SLFBC. This vacuum bearing 360 is mounted within housing 310 and is held in place by a clamp 362 , which rotates with shaft 312 . Shaft 312 also includes circumferentially extending snap ring apertures 319 for holding bearing 321 in longitudinal alignment with shaft 312 . Stater 324 of the axially aligned motor 325 fits within a recess 339 of housing 310 and 337 of housing 320 , as seen in FIG. 16 .
[0040] The coolant supply tube 332 has a first threaded end 335 which threadably extends into the union 331 , as illustrated in FIG. 16 , and receives cooling fluid, such as water, through an inlet connector 340 . The stationary concentric tube 332 is held in longitudinally spaced alignment with an annular space between the outer diameter of tube 332 and the inner diameter of aperture 314 of rotary drive shaft 312 by its coupling to union 331 at one end and the extension through aperture 213 in anode 202 , which includes a conventional bushing 221 ( FIGS. 5 and 15 ) between the end 338 of supply tube 332 and aperture 213 as necessary. Union 331 is a commercially available rotating union manufactured, for example, by the Deublin Company of Northbrook, Ill., in their Model 57 Series. The flange 345 of housing 330 receives fasteners, such as bolts or cap screws 347 ( FIG. 16 ), which extend through housing 320 and into housing 310 in a conventional manner for securing housings 330 , 320 , and 310 together, while other suitable fasteners, such as hex bolts or the like, extend through the apertures in flange 50 for securing the assembly 300 to the body 14 of chamber 12 .
[0041] The negative power supply 22 ( FIG. 1 ) for the capacitor(s) 20 charges the capacitor(s) at a rate .at least as fast, if not slightly faster, than the pulse trigger voltage frequency. The power supply should have the same frequency as the trigger pulse rate. They are synchronized by the controller ( FIG. 17 ), such that there is a time delay between the two signals. The main pulse is first to charge the capacitor(s) to the given voltage, followed by the trigger pulse, such that, as soon as the trigger discharges the plasma within chamber 129 of the trigger assembly, the fully charged capacitor 20 discharges through the plasma in the gap “s” ( FIG. 5 ) between the anode edge 204 and cathode 106 effecting generation of soft x-rays within chamber 11 . The x-rays are then transmitted from the trigger assembly through the x-ray filters at window 19 or exit port 40 transparent to the x-ray radiations of the x-ray generator. Chamber 11 may have a plurality of similar windows, such as window 19 ( FIG. 1 ), at various locations around the housing 12 , for the exit of soft x-rays which can be focused external to generator 10 for subsequent use in lithography, crystallography, radiography, or the like, in a conventional manner.
[0042] In order to achieve a high repetition rate of discharge, fast charging of capacitors C 1 and 20 to about −3 kv to about −20 kv from a 500 volt DC ( FIG. 17 ) source is required. A two stage resonant charging circuit is employed for this, as schematically shown in FIG. 17 . The first stage resonantly charges capacitor C 1 to 1000 volts through inductor L 1 , and the second stage resonantly charges capacitor 20 from capacitor C 1 through inductor L 1 using the step up transformer T 1 . The pulser is able to signal the controller (which includes a microprocessor) that a short circuit shunts 20 inside the vacuum chamber by sensing a negative voltage on C 1 . The controller stops to pulse the pulser to prevent potential damage of charging circuitry. To achieve high and controlled repetition rates of vacuum discharge for desired output power, a flexible design of controller and pulser module that can control and deliver high repetition rates up to 100 kHz is desirable. To obtain multiple charging rates from a single pulser circuit, multiplexing multiple pulsers are employed.
[0043] It will become apparent to those skilled in the art that various modifications to the preferred embodiment of the invention as described herein can be made without departing from the spirit or scope of the invention as defined by the appended claims. | A soft x-ray generator includes a unique pulse trigger assembly which reliably and reproducibly provides a plasma to initiate the discharge between a cathode and an anode, and having a cone-shaped geometry. The soft x-ray generator of the present invention also includes a rotating anode which is generally disk-shaped with an outer circumferential edge which can be rotated with respect to the cathode to expose different sections of the anode to the plasma discharge, thereby reducing anode wear and providing longer term operation. Anode erosion is also reduced by the liquid cooling of the anode during use. The generator utilizes a relatively low capacitance for the cathode-to-anode discharge and a relatively high voltage and pulse repetition rate (frequency) to achieve continuous reproducible results. | 7 |
BACKGROUND OF THE INVENTION
This invention relates to a foundation piling system, and more particularly to such a system which enjoys improvements over conventional foundation supports for houses, buildings and the like.
In home and building construction, exterior grade beams, or footings, are often utilized which are formed in ditches, or the like, to support the exterior walls of the building. These concrete grade beams are often poured in conjunction with a continuous slab which extends in the area between the grade beams and can be poured simultaneously with, or separate from, the grade beams.
However, problems are encountered in connection with these type arrangements, especially when the building site contains soil of varying compactness and plasticity. For example, in cases when a building site is extensively graded to level it and soil is moved from one portion of the lot to the other, the soil immediately underneath the removed soil is relatively compact while the soil that is moved to other portions of the building site is relatively loose. This, of course, causes differential movements of the foundation and the grade beams and potential problems with regard to cracking, breaking, or the like.
Several techniques have been suggested to combat these problems. For example, a concrete pier system has been suggested in which relatively deep holes are formed and concrete poured into the holes to form a pier for the exterior grade beam. However, these concrete piers have several disadvantages. For example, the depth to which the beam is formed is often based on a single soil test at one area which is not necessarily representative of the entire area. Thus the pier, although adequate in height for the particular area tested, may be insufficient to adequately support the foundation in other areas having a softer or more plastic soil composition.
Also, the drills used to drill the pier holes do not necessarily clean out the bottom of the holes which causes difficulty in the stability of the beam once it has been poured. Further, the pier drill may encounter soft rock strata or the like which jams the drill and causes undue delays. Still further, upheaval forces, i.e., forces in the upward direction often occur due to the changes in the wetness or the dryness of the soil which causes a poured concrete pier to fail. Still further, in soils having a large percentage of clay there is a certain practical limit on the height of the pier, which does not necessarily support the foundation adequately in this type of environment.
Other techniques for constructing an adequate exterior grade beam support include a post tension technique in which cables are passed through the forms for the grade beams and, after the concrete is poured thereover, are placed in very high tensile stress to increase the resistance of the foundation to cracking or failing. However, these types of techniques require a great deal of labor and are also subject to fail.
SUMMARY OF THE INVENTION
It is therefore an object of the present invention to provide a foundation piling system in which pilings are used which will support a foundation system in soil having a varied composition and moisture content.
It is a further object of the present invention to provide a system of the above type which eliminates the need for drilling a hole in the ground to receive the pilings.
It is a still further object of the present invention to provide a system of the above type in which the pilings are formed of steel pipes.
It is a further object of the present invention to provide a system of the above type in which the pilings extend into concrete grade beams forming a portion of a monolithic system including a concrete slab.
It is a still further object of the present invention to provide a system of the above type in which reinforcing bars are provided for the concrete grade beams and extend through holes in the pilings to add stability and strength to the foundation.
BRIEF DESCRIPTION OF THE DRAWINGS
The above brief description as well as further objects, features and advantages of the present invention will be more fully appreciated by reference to the following detailed description of presently preferred but nonetheless illustrative embodiments in accordance with the present invention when taken in conjunction with the accompanying drawings wherein:
FIG. 1 is a plan view depicting a portion of the foundation piling system of the present invention; and
FIG. 2 is an enlarged sectional view taken along the line 2--2 of FIG. 1.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring to FIGS. 1 and 2 of the drawings, the reference numeral 10 refers in general to the foundation system of the present invention which consists essentially of a concrete slab 12 formed in a rectangular configuration and having a grade beam 14 extending around the margins thereof. The grade beam 14 is formed essentially of concrete and can be formed intergally with the slab 12. Alternatively, the grade beam 14 can be formed separately from the slab 12 in which case, a joint J would be formed at the interface between the grade beam and the slab. The upper surface of the grade beam 14 is coextensive with the upper surface of the slab 12 and the grade beam has a height, or thickness, greater than that of the slab.
A plurality of vertical steel pilings 16 extend from the grade beam 14 and into the ground and are spaced at predetermined intervals, such as nine feet.
A horizontally-extending steel bar 18 extends within the grade beam 14 and adjacent the outer periphery thereof. Four additional horizontally-extending steel bars 20, 22, 24 and 26 are provided in the grade beam 14 and extend in two rows of two bars per row. The bars 20 and 22 extend parallel in a horizontally-spaced, parallel relationship adjacent the upper surface of the grade beam 14, and the bars 24 and 26 extending in a horizontally spaced, parallel relationship and are vertically spaced from the bars 20 and 22, respectively. Each of the bars 18, 20, 22, 24, and 26 extend along the grade beam 14 and each can be formed by overlapping a plurality of sections together before the grade beam 14 is poured.
A plurality of U-shaped stirrups 30 (FIG. 2) extend around the bars 20, 22, 24, and 26 at predetermined spaced intervals along the grade beam 14, such as three feet. The upper end portions of each stirrup 30 are bent inwardly to secure each stirrup to the bars 20 and 22. A plurality of parallel, horizontally-extending dowels 32 extend transversly to the pilings 16 and to the bars 18, 20, 22, 24 and 26 and are also spaced at three feet intervals. The dowels 32 are tied to the bar 18 and to the stirrups 30 by tiewires 33 prior to pouring of the concrete.
A plurality of parallel, horizontally-spaced L-shaped dowels 34 extend over the bars 20 and 22, and around the bar 22 in an abutting relaitonship with a vertical leg of the stirrups 30, respectively. The dowels 34 can be tied to their respective stirrups 30 by tiewires (not shown) if necessary.
The inner and outer side walls of the grade beam 14 are tapered inwardly and a pair of styrofoam strips 36 and 38 are disposed adjacent the latter walls, respectively, and serve to insulate the foundation from the moisture and temperature of the soil surrounding same. A corrugated cardboard board filler 40 is disposed at the bottom of the grade beam 14 and acts to absorb any upheaval forces from the soil acting against the grade beam.
According to a preferred embodiment, the piling 16 are formed by a plurality of 12 feet sections of 3 inch diameter upset seamless steel tubing preferably of a type N-80 quality (high carbon alloy steel) having a tensile stress limit of approximately 180,000 lbs. Adjacent sections of the piling are connected by a connector tube (not shown) one foot in length and 23/8 inches in diameter, with the connector tube being welded to the inner surfaces of the corresponding ends of adjacent piling sections and extending in the ends thereof.
The bars 18, 20, 22, 24 and 26, the dowels 32 and 34, and the stirrups 30 can be be fabricated of steel and can be sized anywhere from a number three to a number five bar, which is standard nomenclature in the industry.
In the construction of the foundation system of the present invention, the pilings 16 are driven into the ground after a 12-24 inch starter joint (not shown) is placed in the ground. A plug is inserted in the starter joint to provide a solid bearing member and to keep the soil from traveling up the joint after it is driven into the ground. The pilings 16 are driven by a conventional pile driver into the ground until absolute refusal is encountered, i.e. until the pilings 16 cannot be driven any further into the ground; or to practical refusal when a piling does not stop driving but yet is at a depth sufficient to support well in excess of the static load of the foundation system 10 and the house.
During the driving of the pilings 16 into the ground, a pressure bulb is formed by the compacting soil which further adds to the stability of the pilings 16 and this, along with the skin friction of the pilings, can support the foundation system 10 and the house. Alternatively, the pilings 16 can be driven with a predetermined amount of energy which can be calculated based on the soil conditions to ensure that an adequate load strength is obtained.
After the pilings 16 have been placed around the periphery of the site at predetermined intervals, such as nine feet, the bars 22 and 26 are strung through openings formed in the pilings 16 as shown in FIG. 2 and thus extend in a rectangular configuration as shown in FIG. 1. The other bars 18, 20, and 24 are placed in the positions shown along with the stirrups 30 and the dowels 32 and 34. The stirrups 30 hold the bars 20, 22, 24, and 26 in place and the dowels 32 are tied to the stirrups 30 and to the bar 18. The styrofoam strips 36 and 38 and the cardboard 40 are placed in position and the slab 12 and the grade beam 14 poured. The forms for the concrete are such that a shoulder 42 is formed in the outer corner of the grade beam 14 to provide a space for the exterior wall of the building. The normal level of the ground is shown by the reference letter G, while after the foundation of the present invention is poured, fill dirt can be filled around the grade beam as shown by the reference letters F.
Several advantages result from the system of the present invention. For example, the bars 22 and 26 extending through the pilings 16 add stability and strength to the system while the dowels 32 and 34 and the stirrups 30 not only reinforce the concrete grade beam 14, but act as supports for the bars 20, 22, 24, and 26 prior to the pouring of the concrete. Also, the pilings 16 can be driven to a great depth through several layers of soft rock strata in a fairly simple and easy manner, and due to their low surface friction, resist upheaval forces since the latter cannot "grab" the pilings and cause damage thereto. Further, the cardboard 40 provides insulation and acts as a spacer to accommodate any upheaval forces in the ground. The tapered configuration of the walls of the grade beam 14 prevents any upheaval on the foundation 12 and causes a shear at the base of the grade beam 14 of any soil tending to move upwardly due to swelling or the like.
It is understood that several variations may be made in the foregoing without departing from the scope of the invention. For example in situations where an extremely deep strata must be penetrated, an I beam or an H-beam of mild steel may be utilized as a piling which encounters less resistance on the driven end than the tubular pilings 16. In this case the bars would be inserted through appropriate holes formed in the flanges of the I-beams or welded to the side edges thereof.
Also, in the event that 50% or more of the grade is formed by fill dirt, horizontal grade beams on twelve feet centers can be formed through the slab extending both longitudinally and traversely to add further strength to the system. As a further option, number three steel bars on sixteen inch centers can be formed through the slab 12 to form a steel mat in the center of the slab to add further strength.
It is noted that the system of the present invention is not limited to the particular foundation disclosed but is equally applicable to a floating slab, a standard pier and beam, or supporting slab system, all conventional in the art.
Other modifications, changes and substitutions are intended in the foregoing disclosure and in some instances some features of the invention will be employed without a corresponding use of other features. Accordingly, it is appropriate that the appended claims be construed broadly and in a manner consistent with the spirit and scope of the invention therein. | The present invention is a foundation piling system in which pilings are used which support a foundation system in soil having a varied composition and moisture content which eliminates the need for drilling a hole in the ground to receive pilings formed of steel pipes. The pilings extend into concrete grade beams forming a portion of a monolithic system including a concrete slab. | 4 |
INCORPORATION BY REFERENCE
[0001] The present application is a Continuation application of U.S. patent application Ser. No. 12/588,394, filed on Oct. 14, 2009, which is based and claims priority from Japanese Patent Application No. JP 2008-293191, filed on Nov. 17, 2008, the entire contents of which is incorporated herein by reference.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The present invention relates to a semiconductor device and a method of manufacturing the semiconductor device.
[0004] 2. Description of the Related Art
[0005] A semiconductor package (a semiconductor device) includes a semiconductor chip and a wiring board on which the semiconductor chip is mounted. The semiconductor chip is provided with a bump formation surface on which protruding bumps are formed. Solder, for example, is used as a material for the bumps. The semiconductor chip is mounted on the wiring board by using the bump formation surface.
[0006] In such a semiconductor device, stress is applied to the semiconductor chip and the bumps at the time of mounting the semiconductor chip or after the mounting in some cases. For example, in a case where flux is used to form the bumps, the semiconductor chip is mounted on the wiring substrate by a heat treatment such as an IR reflow treatment. In this mounting, stress sometimes occurs due to such reason as a difference in thermal expansion coefficient between the bump portions and the other portions. Such stress may cause a bump crack or a chip crack. Thus, reduction of such stress is desired.
[0007] As a related art, Japanese Patent Application Publication No. 2007-242782 discloses a technique relating to a semiconductor device in which bumps serving as external connecting terminals are joined to a semiconductor substrate. An object of this technique is to reduce or absorb stress which the bumps receive from a mounting board and at the same time ensure stable electrical connection.
[0008] Another related art is Japanese Patent Application Publication No. 2007-142017. This patent document discloses that bumps between a chip and a wiring board are arranged in concentric circles, and have diameters changing from the center circle toward the outermost circle in order to disperse stress occurring in the circumferential portion of the chip.
[0009] In some cases, stress occurring in a bump formation surface of a semiconductor chip notably increases due to a difference in the density of bumps arranged on the bump formation surface.
[0010] FIG. 1 is a schematic view, showing an example of an arrangement of bumps 101 on a bump formation surface 102 . In the example shown in FIG. 1 , the bumps 101 are uniformly arranged. In this case, there is no difference in the density of the bumps, and thus stress relating to the density of the bumps occurs less.
[0011] FIG. 2 is a schematic view showing another example of an arrangement of the bumps 101 on the bump formation surface 102 . In the example shown in FIG. 2 , the bump formation surface 102 includes a first region 103 in which the bumps 101 are densely arranged and a second region 104 in which the bumps 101 are sparsely arranged. FIG. 3 shows a simulation result of a stress distribution which occurs at the time of mounting a semiconductor chip and after the mounting. The simulation result in FIG. 3 is obtained by use of a semiconductor chip having the bump formation surface 102 shown in FIG. 2 . As shown in FIG. 3 , stress occurring portions 105 occur around a border between the first region 103 and the second region 104 .
[0012] Apparently, there is a problem that stress at a problematic level for a product occurs when the arrangement of the bumps 101 has a notable density difference as shown in FIG. 3 .
SUMMARY
[0013] A semiconductor device according to the present invention includes: a wiring board ( 1 ); and a semiconductor chip which includes a bump formation surface ( 7 ) having a bump group ( 3 ) formed thereon and which is mounted on the wiring board ( 1 ) by using the bump group ( 3 ). The bump formation surface ( 7 ) includes: a first region ( 9 ) in which an area density of a region having bumps ( 3 ) arranged therein is a first density; a second region ( 10 ) in which an area density of a region having bumps ( 3 ) arranged therein is a second density lower than the first density; and a third region ( 11 ) provided in a border portion between the first region ( 9 ) and the second region ( 10 ). In the third region ( 11 ), an area density of a region having bumps ( 3 ) arranged therein is higher than the second density and is lower than the first density.
[0014] According to the present invention, stress occurring between the first region ( 9 ) and the second region ( 10 ) due to a difference in the density of the bumps is reduced by providing the third region ( 11 ). Thus, a bump crack and a chip crack due to the stress can be suppressed.
[0015] A semiconductor chip according to the present invention includes a bump formation surface ( 7 ) which faces a wiring board ( 1 ) when mounted on the wiring board ( 1 ) and which has a bump group ( 3 ) formed thereon, the bump group ( 3 ) electrically connected to the wiring board ( 1 ). In the semiconductor chip, the bump formation surface ( 7 ) includes: a first region ( 9 ) in which an area density of a region having bumps ( 3 ) arranged therein is a first density; a second region ( 10 ) in which an area density of a region having bumps ( 3 ) arranged therein is a second density lower than the first density; and a third region ( 11 ) for reducing stress occurring at the time of mounting the semiconductor chip on the wiring board ( 1 ). The third region ( 11 ) is provided in a border portion between the first region ( 9 ) and the second region ( 10 ). In the third region ( 11 ), an area density of a region having bumps ( 3 ) arranged therein is higher than the second density and is lower than the first density.
[0016] A wiring board according to the present invention includes a chip mounting surface ( 12 ) on which a semiconductor chip is to be mounted. Electrode terminals ( 5 ) are arranged on the chip mounting surface ( 12 ) in a pattern corresponding to the bump formation surface ( 7 ) of the semiconductor chip described above.
[0017] A method of manufacturing a semiconductor device according to the present invention includes the steps of: preparing a wiring board ( 1 ) including an electrode terminal group ( 5 ); preparing a semiconductor chip including a bump formation surface ( 7 ) which has a bump group ( 3 ) formed thereon, the bump formation surface ( 3 ) including a first region ( 9 ) in which an area density of a region having bumps ( 3 ) arranged therein is a first density, a second region ( 10 ) in which an area density of a region having bumps ( 3 ) arranged therein is a second density lower than the first density, and a third region ( 11 ) which is for reducing stress occurring at the time of mounting the semiconductor chip on the wiring board ( 1 ), which is provided in a border portion between the first region ( 9 ) and the second region ( 10 ), and in which an area density of a region having bumps ( 3 ) arranged therein is higher than the second density and is lower than the first density; and mounting the semiconductor chip on the wiring board ( 1 ) by heat treatment so that the bump group ( 3 ) faces the electrode terminal group ( 5 ).
[0018] The present invention provides a semiconductor device capable of reducing stress even when an arrangement of bumps has a density difference, and a method of manufacturing such a semiconductor device.
BRIEF DESCRIPTION OF THE DRAWINGS
[0019] FIG. 1 is a schematic view showing an example of an arrangement of bumps on a bump formation surface.
[0020] FIG. 2 is a schematic view showing another example of the arrangement of the bumps on the bump formation surface.
[0021] FIG. 3 is a simulation result of a stress distribution.
[0022] FIG. 4 is a cross-sectional view showing a semiconductor device according to a first embodiment.
[0023] FIG. 5 is a schematic view showing an arrangement of bumps in a part of a bump formation surface.
[0024] FIG. 6 is a simulation result of a stress distribution in the first embodiment.
[0025] FIG. 7 is a simulation result of the amount of stress.
[0026] FIG. 8 is a schematic view showing a bump formation surface of a semiconductor device according to a second embodiment.
[0027] FIG. 9 is a simulation result which shows a relation between bump size and stress.
[0028] FIG. 10 is a schematic view showing a bump formation surface of a semiconductor device according to a third embodiment.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
First Embodiment
[0029] A first embodiment according to the present invention will be described with reference to the drawings. FIG. 4 is a cross-sectional view showing a semiconductor device according to the present embodiment.
[0030] As shown in FIG. 4 , the semiconductor device of the present embodiment includes a wiring board and a semiconductor chip 13 . The wiring board 1 has a chip mounting surface 12 . On the chip mounting surface 12 , multiple electrode terminals 5 are formed as an electrode terminal group. Meanwhile, the semiconductor chip 13 includes a chip substrate 2 having a semiconductor integrated circuit formed thereon. The chip substrate 2 is provided with a bump formation surface 7 . Multiple bumps 3 are formed on the bump formation surface 7 as a bump 3 group. The semiconductor chip 13 is mounted on the wiring board 1 so that the bump formation surface 7 would face the chip mounting surface 12 . An arrangement pattern of the bumps 3 on the bump formation surface 7 is the same as an arrangement pattern of the electrode terminals 5 on the chip mounting surface 12 . The bumps 3 and the electrode terminals 5 are electrically connected to each other. Moreover, a space between the semiconductor chip 13 and the wiring board 1 is sealed with sealing resin 4 . Connecting parts between the semiconductor chip 13 and the wiring substrate 1 are protected by the sealing resin 4 .
[0031] As shown in FIG. 4 , the semiconductor device according to the present embodiment is a so-called flip-chip semiconductor package.
[0032] FIG. 5 is a schematic view showing the arrangement of the bumps in a part of the bump formation surface 7 . As shown in FIG. 5 , the bump formation surface 7 includes a first region 9 , a second region 10 , and a third region 11 .
[0033] In the first region 9 , the area density of a region having the bumps 3 arranged thereon is a first density.
[0034] In the second region 10 , the area density of a region having the bumps 3 arranged thereon is a second density. The second density is lower than the first density.
[0035] The third region 11 is provided to suppress stress occurring due to a difference in densities of the bumps 3 between the first region 9 and the second region 10 . The third region 11 is located in a border portion between the first region 9 and the second region 10 . In the third region 11 , the area density of a region having the bumps 3 arranged thereon is a third density. The third density is higher than the second density, and is lower than the first density. In other words, the area density increases in the regions having the bumps 3 arranged thereon in the order of the first region 9 , the third region 11 , and the second region 10 .
[0036] Note that, the area density is the proportion, in a predetermined region, of the area of a portion where the bumps are arranged to the sum of the area of the portion where the bumps are arranged and the area of a portion where no bumps are arranged.
[0037] Moreover, the bumps 3 in the first region 9 , the second region 10 , and the third region 11 all have the same size. In other words, the first region 9 , the second region 10 , and the third region 11 have different numbers of the bumps 3 per unit area. Accordingly, the area densities of the respective regions having the bumps arranged thereon are different from each other. In each of the first region 9 , the second region 10 , and the third region 11 , the bump 3 are arranged at almost equal intervals.
[0038] To manufacture a semiconductor device such as one described above, firstly, the semiconductor chip 13 and the wiring substrate 1 are prepared. In the preparation of the semiconductor chip 13 , the bumps 3 are formed by using flux. Thereafter, the semiconductor chip 13 is mounted on the wiring board 1 . At this time, a heat treatment such as an IR reflow treatment is performed.
[0039] In the heat treatment, stress is likely to occur due to a difference in thermal expansion coefficients between portions corresponding to the bump 3 and the other portions. However, in the present embodiment, the third region 11 is provided in the border portion between the first region 9 and the second region 10 as shown in FIG. 5 . Thus, the density of the bumps 3 in the bump formation surface 7 changes stepwisely. By this arrangement, the portion where the density of the bumps 3 suddenly changes is eliminated, thereby reducing the stress. As a result a bump crack and a chip crack are suppressed.
[0040] FIG. 6 shows a simulation result of a stress distribution occurring in the present embodiment. Stress occurring portions 8 occur in a border portion between the first region 9 and the third region 11 and in a border portion between the third region 11 and the second region 10 . The stress occurring portions 8 are dispersed compared to a case where the third region 11 is not provided (see FIG. 3 ).
[0041] FIG. 7 shows a simulation result of the amount of stress. In FIG. 7 , the vertical axis indicates the amount of stress, and the horizontal axis indicates the present embodiment (the first embodiment) and Comparative Example 1. Comparative Example 1 is an example in which the region corresponding to the third region 11 is replaced with the second region. In FIG. 7 , a white circle for the first embodiment indicates stress in the border portion between the first region 9 and the third region 11 , and a black circle for the first embodiment indicates stress in the border portion between the third region 11 and the second region 10 . As to Comparative Example 1, a white circle and a black circle each indicate stress in a portion corresponding to the portion indicated for the present embodiment.
[0042] As shown in FIG. 7 , the amount of the stress is reduced in the present embodiment compared to Comparative Example 1 in both the border portion between the first region 9 and the third region 11 and the border portion between the third region 11 and the second region 10 . The fact that the stress is reduced by providing the third region 11 is confirmed from the simulation result.
[0043] In the present embodiment, the case where the semiconductor chip 13 is flip-chip mounted on the wiring substrate 1 is described. However, the present invention is not limited to this, and it should be understood that the present invention can be applied to any case where a semiconductor chip is mounted on a chip, a substrate or the like by using bumps.
Second Embodiment
[0044] Next, a second embodiment will be described. FIG. 8 shows a bump formation surface 7 of a semiconductor device according to the second embodiment. In the present embodiment, the size and the arrangement of bumps 3 in a third region 11 are different from those in the first embodiment. The other points may be the same as the first embodiment, and thus the detailed description thereof is omitted here.
[0045] In the present embodiment, as in the case of the first embodiment, the region of the third region 11 having the bumps 3 arranged thereon has an area density (third density) which is higher than a second density and is lower than a first density. However, in the present embodiment, the number of the bumps 3 arranged per unit area in the third region 11 is the same as that in the second region 10 . Meanwhile, the size of each of the bumps 3 arranged in the third region 11 is larger than the size of each of the bumps 3 arranged in the first region 9 and the second region 10 . Note that, the bumps 3 in the first region 9 and the bumps 3 in the second region 10 are all the same in size.
[0046] In other words, in the present embodiment, the bumps 3 of the third region 11 and the bumps 3 of the second region 10 are different in size. Thus, the density of the bumps in the bump formation surface 7 changes stepwisely.
[0047] In the present embodiment, stress can also be reduced, and a bump crack and a chip crack can be suppressed, as in the case of the first embodiment.
[0048] FIG. 9 is a simulation result which shows a relation between the bump size in the third region 11 and stress. In FIG. 9 , the horizontal axis indicates the size of each of the bumps 3 arranged in the third region 11 , and the vertical axis indicates the amount of stress. Moreover, as in the case of the first embodiment, each of white circles indicates stress in the border, portion between the first region 9 and the third region 11 , and each of black circles indicates stress in the border portion between the third region 11 and the second region 10 . The bump size is 1.00 in the first region 9 and the second region 10 . The number of the bumps per unit area in the third region 11 is the same as that in the second region 10 .
[0049] As shown in FIG. 9 , the amount of stress is the smallest when the bump size in the third region 11 is set at 1.15, and is the largest when the bump size in the third region 11 is set at 0.85. Thus, the fact that the stress is reduced by increasing the bump size in the third region 11 is confirmed.
Third Embodiment
[0050] Next, a third embodiment of the present invention will be described. FIG. 10 shows a bump formation surface 7 of a semiconductor device according to the third embodiment. In the present embodiment, a bump group provided on the bump formation surface 7 includes actual bumps 3 - 1 and dummy bumps 3 - 2 . The other points maybe the same as the above-described embodiments, and thus the detailed description thereof is omitted here.
[0051] The actual bumps 3 - 1 are bumps used for electrical connection between a semiconductor chip 13 and a wiring board 1 . On the other hand, the dummy bumps 3 - 2 are provided to control the area density of a region where the bumps are arranged, and are not used for the electrical connection between the semiconductor chip 13 and the wiring board 1 .
[0052] According to the present embodiment, the stress can be reduced by the same effects as the above-described embodiments. In addition, the area density of a region where the bumps 3 are arranged can be controlled by the dummy bumps 3 - 2 . Accordingly, the present embodiment is advantageous in that a layout of the bumps 3 is less restricted.
[0053] Although the inventions has been described above in connection with several preferred embodiments thereof, it will be appreciated by those skilled in the art that those embodiments are provided solely for illustrating the invention, and should not be relied upon to construe be appended claims in a limiting sense. | A semiconductor device includes a wiring board, a semiconductor chip mounted on the wiring board, the semiconductor chip including a bump formation surface, a plurality of first bumps provided within a first region of the bump formation surface, the first bumps being arranged in a first area density, a plurality of second bumps provided within a second region of the bump formation surface, the second bumps being arranged in a second area density, and a plurality of third bumps arranged between the first region and the second region of the bump formation surface in a two-dimensional array. The plurality of third bumps are arranged in a third area density being higher than the second area density and being lower than the first area density. | 7 |
RELATED APPLICATION
This is a Divisional Application of prior U.S. patent application Ser. No. 09/126,999, Filed Jul. 31, 1998 by Tang, now U.S. Pat. No. 5,994,976, dated Nov. 30, 1999.
FIELD OF THE INVENTION
The field of the present invention relates generally to cable television and RF signal distribution equipment, and more specifically to multi-taps and similar devices.
BACKGROUND OF THE INVENTION
CATV systems use hundreds of multi-taps to provide RF and AC power to subscribers through coaxial drops. The multi-taps are eventually upgraded or replaced due to damage, product improvement, etc. Since the housings of the multi-taps are fixed in length (typically about four inches) and it is very difficult to remove the connectors from the coaxial cable, most installers simply cut the coaxial cable at the connector base and install another connector in the cable. Since a multi-tap housing length is fixed, the shortened coaxial cable might not reach and fit into the multi-tap. A prior solution is to replace the removed shorter housing with a relatively longer multi-tap housing. For example, a nine-inch multi-tap housing is long enough to accommodate the upgrade of all standard multi-taps in the industry. It is known in the art to utilize this idea by simply using a single base plate or top plate in the longer housing.
Furthermore, different amounts of RF power must often be tapped off to different users because they are at respectively different distances from a multi-tap. Whereas this could be affected by designing the circuits in the multi-tap in such a manner that they provide the required levels of power to each subscriber input port to which the cables are coupled, this would be very expensive. Therefore, it has been customary for all of the tap-offs of a multi-tap to provide the same amount of power. Since the circuits are mounted on the inside of a removable cover known as a tap plate for the multi-tap, it is necessary to change tap plates to supply a desired amount of tap-off power to a group of subscribers.
There are situations, such as in apartment houses, wherein a large number of multi-taps are required. With present multi-taps in which input ports are at one end and output ports at the other, the interconnections such between a plurality of multi-taps for accommodating a huge number of subscribers can be rather complicated, and require a huge amount of space for mounting the multi-taps. This is an additional problem to those mentioned above.
SUMMARY OF THE INVENTION
The present invention overcomes the problems in the art by providing a dual compartment nine-inch housing in one embodiment that provides backward compatibility with prior single housing tap plates. This feature allows flexibility for the CATV installers to use types of tap plates in a dual compartment housing, e.g., equalizers, filters, with various functionality dB value taps, etc. Also, double the number of subscriber ports can be provided due to the dual compartment housing configuration. It also can use the current single compartment tap plate in the new nine-inch dual compartment housing.
In other words, the provision of two compartments makes it possible to provide one compartment with a standard tap plate and the other compartment with a tap plate providing entirely different functions.
In accordance with this invention, ends of first and second multi-taps, each having its own tap plate, are joined together and constructed in such manner that RF signals and AC power can flow from an input port at the unjoined end of the first multi-tap, through the first and second multi-taps to an output port at the unjoined end of the second multi-tap, or back through both multi-taps via micro strip lines in each multi-tap to an output port at the unjoined end of the first multi-tap, for example. Thus, there is an input port and an output port at the unjoined end of the first box that are close together so as to make it easy to connect them to the cut ends of an underground cable.
When the multi-tap is configured so that the desired flow of RF signals is out of the output port at the unjoined end of the second multi-tap and not back through the multi-taps via the microstrip lines referred to, it has been found that these microstrip lines interfere with the desired flow of signals. In order to prevent this from occurring, special conductive ground shields are provided that can be placed over the microstrip lines in each multi-tap.
As indicated, the present dual compartment housing permits great flexibility to an installer. Conventional tap plates provide tap-offs for either two, four, or eight subscribers, respectively, and may each provide different tap-off power. Accordingly, the use of the present dual compartment will reduce the inventory requirements of the cable installer.
BRIEF DESCRIPTION OF THE DRAWINGS
Various embodiments of the invention are described in detail below with reference to the drawings, in which like items are indicated by the same reference designation, wherein:
FIG. 1 is a bottom view of a multi-tap incorporating this invention with the covers in place;
FIG. 2 is a bottom view of a multi-tap of this invention with the covers removed and the RF and AC passing through the multi-tap and back to the end where they were introduced;
FIG. 3 is a view of the inside of a cover having a circuit board of the type used to distribute RF signals and AC power to outlets for users' cables;
FIG. 4 is a view of the inside of a cover that simply passes RF signals and AC power through its multi-tap;
FIG. 5 is a view of the top of a multi-tap incorporating this invention;
FIG. 6 is a view of the end of a multi-tap of this invention having, both input and output cable connectors;
FIG. 7 is a view of the end of a multi-tap of this invention that has a single output cable connector;
FIG. 8 is a view of one side of a multi-tap of this invention;
FIG. 9 is a view of the side of a multi-tap of this invention opposite to that shown in FIG. 8;
FIGS. 10A through 10H illustrate paths that can be followed by RF and AC in a multi-tap of this invention;
FIG. 11 illustrates another way in which multi-taps of this invention can be coupled together;
FIG. 12 illustrates a problem in vertically coupling multi-taps of the prior art together;
FIG. 13 is a bottom view of a preferred embodiment of a multi-tap of this invention in which the RF and AC only pass through the multi-tap in one direction;
FIG. 14 is a bottom view of a preferred embodiment of a multi-tap of this invention in which RF and AC pass through the multi-tap in one direction and then pass through it in the opposite direction;
FIG. 15 is an enlarged view of a portion of FIG. 13;
FIG. 16 is an exploded assembly view of a preferred embodiment of cable seizure means of this invention.
FIG. 17A is a schematic illustration of a switch using an end of a transmission line as the switching element when the switch is closed; and
FIG. 17B is a schematic illustration of a switch using an end of a transmission line as the switching element when the switch is open.
DETAILED DESCRIPTION OF THE INVENTION
FIG. 1 shows the bottom of a multi-tap 2 of the invention that one would see from the ground if the multi-tap were used with an above ground system cable. In its preferred form, the multi-tap 2 is comprised of two sections 4 and 6 that are joined together by a wall as indicated at 8. Each of the sections 4 and 6 have compartments therein that are not seen in this view because they are covered by tap plate covers 10 and 12 respectively that are attached by bolts 14. The possible inward and outward flows of RF signals and AC power are indicated by arrows. The RF and AC can enter the section 4 at an end input port 46 thereof as indicated by an arrow 16 or they can enter at a side input port 48 thereof as indicated by an arrow 18. After flowing through the sections 4 and 6 of the multi-tap 2, they can exit from an output port 82 at the end of the section 6 as indicated by an arrow 20 or from an output port 78 at its side as indicated by an arrow 22. Alternatively, the RF and AC may be returned through the sections 6 and 4 so as to exit at an output port 84 at the end of the section 4 as indicated by an arrow 24 or from an output port 86 at its side as indicated by an arrow 26. Whichever path the RF and AC follow, they may be coupled to coax connectors at locations 25, 28, 30, 32, 34, 36, 38 and 40 in the tap plate cover 12 for connection to user cables. Tap plates can be provided with different numbers of connectors 42, but in FIG. 1 only two connectors 36 and 38 are shown. The other connectors are closed by protective caps at the locations 25, 28, 30, 32, 34, and 40.
In this particular embodiment of this invention; no outlets for RF and AC are provided in the cover 10, but if desired they could be located at any of the circles 44. In this case, the outlets of the tap plate cover 12 could be provided with different amounts of the RF power than outlets of the tap plate cover 10. Alternatively, the tap plate cover 10 of section 4 could contain circuits for performing functions other than distributing RF and AC to user cables.
The fact that the RF and AC can enter the multi-tap 2 at a point indicated by the arrow 16 and can leave at a point indicated by the arrow 24 that are closer together than in a typical multi-tap is because they are at the same end of the multi-tap 2. This permits them to be easily coupled to the cut ends of a buried system cable in the bottom of a housing of small cross-section.
Reference is now made to FIG. 2 for a description of the circuitry for guiding the RF and AC along the paths just described in connection with FIG. 1, whereby as will be shown, the paths are interconnected single line conductors for RF signals and AC power. In FIG. 2, the tap plate cover 10 and the tap plate cover 12 are removed so that compartments 4' and 6' respectively contained in the sections 4 and 6 are visible. A cut end of a system cable, not shown, that carries RF and AC is to be coupled to the input port 46 or to the input port 48 so as to introduce the RF and AC into the compartment 4' in the direction of the arrows 16 or 18 respectively. The shield of the coax cable would be connected to the multi-tap 2 so that it is grounded, but the central conductor, not shown, would extend into the compartment 4' and into a passageway in a cable seizure means 50 where it is clamped by a screw 52. The cable seizure means 50 serves as an internal connector. As shown, the screw 52 would clamp the central conductor of a cable coupled to the input port 46, but the screw and passageway can be rotated 90° so as to clamp the central conductor of a cable coupled to input port 48.
In either position of the cable seizure means 50, the RF and AC appear at its output 54 and are normally conducted to an input 56 of a nearly identical cable seizure means 58 via a microstrip transmission line 60. Since the cable seizure means 58 permanently connects its input 56 to a conductor 62 that is thrust into a passageway, not shown, within it, a screw like 52 is not required, and the conductor 62 is soldered to the passageway.
The RF and AC on the conductor 62 are transmitted to the compartment 6' by passing them through a passageway 64 shown in dashed lines so as to in effect form a coaxial cable. A cable seizure means 66 that is like the cable seizure means 58 connects the conductor 62 to its output 68, and a microstrip or other type of transmission line 70 is normally connected between the output 68 of the cable seizure means 66 and an input 72 of a cable seizure means 74 that is like the cable seizure means 50. When a screw 76 in the cable seizure means 74 is in the position shown, a passageway, not shown, extending through the seizure means 74 is aligned with the arrow 22 so as to be able to receive the central conductor of a cable coupled to the output port 78 in one end or a conductor 80, to be described, in the other end. Of course, only one conductor will be present at a time. By rotating the screw 76 and passageway 90°, the center conductor of a cable coupled to the output port 82 can be inserted in the passageway and clamped by tightening the screw 76.
A port plug like 85 that is attached to the input port 48 is attached to any port of the multi-tap 2 to which a cable is not connected in order to prevent insects, dirt or moisture from entering either of the compartments 4' or 6'.
When it is desired to return the RF and AC back through the compartments 6' and 4' to a cable coupled to the output port 84 or to a cable coupled to the output port 86 at the other end of the multi-tap 2, the conductor 80 is inserted into the passageway, not shown, in the cable seizure means 74 and clamped by the screw 76. The conductor 80 is connected to a free end 88 of a microstrip 90, and the other end 92 of the microstrip line 90 is connected to one end of a conductor 94 that extends through a passageway 96 shown in dashed lines between the compartments 6' and 4' so as to in effect form a coaxial cable. The other end 98 of the conductor 94 is connected to an end 100 of a microstrip 102, and the other end 104 of the microstrip 102 is connected to an input 106 of a cable seizure means 108 that is like the cable seizure means 50. The cable seizure means 108 has a screw 110, and a passageway, not shown, intersecting the screw, as in the cable seizure means 50 and 74. By rotation of the screw 110 and the unseen passageway, the input 106 may be connected to the center conductor of a cable coupled to the output port 84 or to the center conductor of a cable coupled to the output port 86.
Should it be desired to have the RF and AC exit the compartment 6' via a cable coupled to the output port 82 or via a cable coupled to the output port 78, the conductor 80 is removed from the unseen passageway in the cable seizure means 74. In this situation, however, the transmission of RF may be adversely affected by coupling between the microstrip 70 in the compartment 6', and possibly other components connected to it, and the microstrip 90 and by coupling between the microstrip 60 in the compartment 4', and possibly other components connected to it, and the microstrip 102. In order to prevent such coupling, a metal shield 112 is mounted in the location as indicated by a dashed line 112' by screws passing through holes 114 and 116 in the shield 112 and threaded into holes 114' and 116' in the body of the multi-tap 2 respectively. The shield 112 is equipped with fingers 118 at one end that make spring contact with the inside of the compartment 6' so as to make a good ground connection. Similarly, a metal shield 120 is mounted within the compartment 4' in a location indicated by a dashed line 120' by screws passing through holes 122 and 124 and threaded into holes 122' and 124' respectively. Fingers 126 make spring contact with the inside of the compartment 4' so as to make a good ground connection.
FIG. 3 illustrates the underside of the tap plate cover 12 that closes the open side of the compartment 6'. As explained in U.S. Pat. No. 5,677,578 issued on Oct. 14, 1997, and which is incorporated by reference herein to the extent it does not conflict herewith, a post 128 is connected to the input of a circuit on a circuit board 130, and a post 132 is connected to the output of the circuit. The posts 132 and 128 are located so that they are respectively inserted into socket spring inserts 128' and 132' in the cable seizure means 66 and 74 (see FIG. 2) when the tap plate cover 12 closes the compartment 6'. The socket spring insert 128' is formed in the top of a metal cylinder or seizure socket having a passageway or hole, not shown, in which the conductor 62 is soldered. The seizure socket is connected by a normally closed switch 134 to the output 68. With reference to FIGS. 2 and 3, a cam spring cap 136 from the body of the cable seizure means 66 is pushed down by the circuit board 130 so as to open the switch 134 and disconnect one end of the microstrip 70 preferably just after electrical contact is made between the post 132 and the socket spring insert 128'. Thus, in a preferred embodiment of this invention, the cable seizure means 66 is an input to two switches, a first switch being the switch 134 and the second switch being formed by the socket spring insert 132' and the post 128. When the tap plate cover 12 is not in position, the first switch is closed so as to connect the conductor 62 to the microstrip 70, and the second switch is open. As the cover 12 is closing the compartment 6', the second switch is closed before the first switch is opened so as not to even momentarily interrupt the flow of R.F. and A.C. to downstream users. When the tap plate cover 12 is being opened, the second switch is closed so as to connect the conductor 62 to the input of its circuit before the first switch is opened so as to ensure that there will not be an interruption in the flow of R.F. and A.C. to downstream users.
Since the components of the cable seizure means 74, 50, and 58 operate in the same way in response to the positioning of a tap plate cover as has just been described, explanation of their operation is not necessary. Their switches are also designated by 134 and their cam spring caps by 136 as in the description just made of the cable seizure device 66.
Reference is now made to FIGS. 2 and 4. FIG. 4 illustrates the underside of the cover 10 in which an electrical connector post 138 is connected to the input of a microstrip 140 on a printed circuit board not having taps, and an electrical connector post 142 is connected to the output of the microstrip 140. When the cover 10 is positioned so as to close the compartment 4' in FIG. 2, the electrical connector post 142 slides into a socket spring insert 138' in the cable seizure means 50, and the electrical connector post 138 slides into a socket spring insert 142' in the cable seizure means 58. Since the switches 134 are normally closed, the microstrip 60 is in the circuit until the cover 10 is positioned to close the compartment 4' at which point the microstrip 140 is substituted for it. It will be understood that in accordance with one aspect of this invention, a circuit board like 130 on the cover 12, or an entirely different circuit board could be substituted for the microstrip 140.
FIG. 5 shows the top of the multi-tap 2 as it would appear when used with an above ground system cable. Clamps 144 and 146 are used to hold it in position.
FIG. 6 shows the end of the section 4 of the multi-tap 2 that has the input port 46 and the output port 84, and FIG. 7 shows the other end of the multi-tap 2.
FIGS. 8 and 9 are opposing side views of the multi-tap 2.
FIGS. 10A through 10H illustrate by way of arrows different paths that RF and AC may follow in passing through a multi-tap of this invention.
One of the advantages of a multi-tap 2 of this invention is the large number of ways in which a number of them can be coupled together, one of which is as shown in FIG. 11, using coupling cable assemblies 1103 and 1104 for example. This feature would be especially advantageous when a large number of users are in the same building. In FIG. 11, for example, the fact that an output port 86 is provided, which is at the same end of a multi-tap 2 as an opposing input port 48, permits any number of multi-taps 2 to be mounted in vertical columns illustrated by multi-taps 1101A, 1101B . . . 1101N. FIG. 12 shows that two multi-taps 145 and 147 of the prior art cannot be mounted in this manner because input and output ports are on the same side of the multi-tap. Similarly, through use of input port 46 of a multi-tap 2 being coupled to an output port 82 of another multi-tap 2, any practical number of multi-taps 2 can be connected in a horizontal place or in a row.
In the embodiments of the invention thus far described, microstrips are provided in the compartments 4' and 6' for conducting signals through the compartments when the covers are not in place so as not to interrupt the flow to downstream users, but such microstrips are not necessary if a shunt is established around the multi-tap before a cover is removed.
In the dual compartment multi-tap just described, the constructions of the cable seizure means 50, 58, 66, 74 and the transmission lines 60 and 70 are the same as in the aforesaid patent wherein the transmission lines 60 and 70 are mounted on circuit boards that are attached by screws to the cable seizure means at their ends. Electrical contact between ends of the transmission lines 60 and 70 and the adjacent cable seizure means when the covers 10 and 12 are not in place is by way of switches 134 that include a spring contact and other metal components. When the covers 10 and 12 close the compartments 4' and 6' respectively, the cams 136 open the switches 134 by forcing the spring contacts so as to disconnect the ends of the transmission lines 60 and 70. The circuitry on the cover 10 is connected between the cable seizure means 50 and 58, and the circuitry on the cover 12 is connected between the cable seizure means 66 and 74.
In a preferred embodiment of the dual compartment multi-tap of this invention, the ends of transmission lines corresponding to the transmission lines 60 and 70 function as the spring contacts for the switches, and the other metal components for the switches are eliminated. Furthermore, the cable seizure means form an integral unit with the transmission line connected between them so as to ensure the necessary positioning of the transmission line with respect to the cable seizure means.
A preferred embodiment of the dual compartment multi-tap of this invention will now be described by reference to FIGS. 13 through 17. Since the differences between the preferred embodiment and the embodiment previously described by reference to FIGS. 1 through 12 lie in the use of cable seizure means different from the cable seizure means 50, 58, 66, and 74 and in the manner in which the new cable seizure means are coupled to a transmission line, all other elements of structures are shown in FIGS. 13 through 17 in the same way they were shown in FIGS. 1 through 12 and are designated by the same numbers. Since the cable seizure means and their coupling to a transmission line in the compartments 4' and 6' are nearly the same, only the cable seizure means and transmission line of the compartment 4' will be referred to, but except for the cable seizure means as units, corresponding components in the compartments 4' and 6' are identified by like numerals. Furthermore, like components of all cable seizure means are designated by the same numbers.
FIG. 13 corresponds to FIG. 2 in that it is a bottom view of a multi-tap with the tap plate covers 10 and 12 removed so as to show the compartments 4' and 6' that are respectively in the sections 4 and 6. In the compartment 4', cable seizure means 200 and 202 that are mounted at its ends are joined by a bridge member 204 so as to form an integral unit of insulating material. A transmission line 206 is attached to the bridge member 204 at points 208 and 210. The transmission line 206 is bent at intermediate points 212 and 214 on either side of its center so that its end portions 216 and 218 slope upwardly from the plane of the paper. As shown in FIG. 16, and as will be explained in connection with FIGS. 17A and 17B, the tips of the end portions 216 and 218 of the transmission line 206 are thereby respectively in resilient electrical contact with metal cylindrical structures inside cable seizure means 200 and 202. Only hollow cylindrical upper portions 220 and 222, respectively of the structures are visible in FIG. 13. As will be described by reference to FIGS. 13 and 15, the metal cylindrical structure including upper portion 222 of the cable seizure means 202 is connected to the cental conductor 62.
When the cover 10 that is shown in FIG. 4 is placed so as to close the compartment 4', the connector post 142 that is connected to one end of the microstrip 140 therein enters the hollow cylindrical upper portion 220 of the metal cylindrical structure of the cable seizure means 200, and the connector post 138 that is connected to the other end of the microstrip 140 enters the hollow cylindrical upper portion 220 of the metal cylindrical structure of the cable seizure means 202 so that the microstrip 140 is connected between a cable connected to either of the coax connectors 46 and 48 and the central conductor 62 that extends between the sections 4 and 6. Just after this connection is made, the circuit board on which the microstrip 140 is mounted pushes cam 224 of the cable seizure means 200 into contact with the end portion 216 of the transmission line 206 and a cam 226 of the cable seizure means 202 into contact with the end portion 218 of the transmission line 206 so as to break their respective resilient contacts with the metal cylindrical structures of the cable seizure means 200 and 202, respectively. Thus the microstrip 140 on the cover 10 is connected between the cable seizure means 200 and 202 before the transmission line 206 is disconnected therefrom, thereby ensuring that the flow of RF and AC to downstream users is not interrupted.
A structure mounted in the compartment 6' is the same as that just described with the exception that the left and right positions of the cable seizure means are interchanged, i.e. a cable seizure means 228 that is like the cable seizure means 202 is located at the left or input end of the compartment 6', and a cable seizure means 230 that is like the cable seizure means 200 is located at the right or output end of the compartment 6'.
The cover 12 for the compartment 6' is that shown in FIG. 3 so as to include circuits for distributing RF and AC power to various users. Connections to these circuits are made by the electrical connector posts 128 and 132 that are located so as to respectively enter the hollow metal upper cylindrical portions 220 and 222 of the cylindrical structures in the cable seizure means 230 and 228, respectively, when the cover 12 is closed. Cams 224 and 226 operate to depress the end portions 216 and 218 respectively of the transmission line 206 in the compartment 6' and break its connections with the upper portions 220 and 222 of the metal cylindrical structures in the cable seizure means 230 and 228.
FIG. 14 is the same as FIG. 13 except that the lead 80 is connected to the cable seizure means 230 so as to conduct RF and AC power back through the multi-tap 2 to cables coupled to either of the coax connectors 84 and 86.
The structure of the cable seizure means 200, 202, the bridge member 204 and the transmission line 206 will now be described. Since all of the cable seizure means are nearly identical, only the cable seizure means 200 needs description. Corresponding structures in all cable seizure means are identified by the same numbers. In FIG. 13, the cable seizure means 200 is shown as having a cover 234 that is attached to a bottom 5 of the compartment 4' by a threaded bolt 236 having a shank that passes through a hole 237 in the cover 234 that is not visible because it is covered by the head of the bolt 236. The bolt 236 is threaded into a riser, not shown, that extends vertically from the bottom 5 of the compartment 4'. An opening 238 in the cover 234 is concentric with a post 240 extending from another vertical riser, not shown, and an opening 242 is concentric with another post 244 extending from a third vertical riser, not shown. A circular opening 246 in the cover 234 surrounds the hollow cylindrical upper portion 220 for the cable seizure means 200. An opening 225 (see FIG. 16) in the cover 234 provides for sliding passage of the cam 224.
When the cover 234 is removed by unscrewing the bolt 236, a base 248 of the cable seizure means 200 appears as shown in FIG. 15. As shown in FIG. 16, the base 248 has hollow cylindrical projections 238' and 242' that respectively extend into the openings 238 and 242 in the cover 234 and which encircle the posts 240 and 244. An opening 237' in the base 248 encircles the shank portion of the bolt 236, but the bolt 236 is not shown in FIG. 15 because it has been removed.
As shown in FIGS. 15 and 16, the hollow cylinder 220 of the metal cylindrical structure within the cable seizure means 200 is above a circular hub 252 of larger diameter. As shown in FIG. 16, a lower cylinder 254 of the metal cylindrical structure for the cable seizure means 200 has the same diameter as the upper cylindrical upper portion 220. The metal cylindrical structure 220, 252, 254 is mounted between the cover 234 and base 248 so that it can be rotated about its axis. A diametric passageway 256 passes through the hub 252, and a set screw 258 is threaded into the hub 252 so as to meet the passageway 256 at right angles. As shown in FIG. 15, the passageway 256 is aligned so that it can receive the central conductor of a cable attached to the coax connector 46, but by rotating the metal cylindrical structure 220, 252, 254 clockwise by 90°, the diametric passageway 252 will be aligned with the central conductor of a cable coupled to the connector 48. In either position the set screw 258 can be tightened against the central conductor of the cable.
The bridge member 204 is molded with the base 248 of the cable seizure means 200 and a base 248 of the cable seizure means 202 to form an integral plastic structure. The base 248 of the cable seizure means 202 is identical to the base 248 of the cable seizure means 200, and its cover 234, FIG. 13, is the same as the cover 234 of the cable seizure means 200. As previously stated, the transmission line 206 is attached at 208 and 210 to the bridge 204, and, as shown in FIG. 16, a conductive plate 262 is attached at the same points so as to extend perpendicularly toward the bottom of the compartment 4'. The plate 262 provides the desired impedance for the transmission line 206.
As shown in FIG. 15, one end of the bridge member 204 meets the base 248 of the cable seizure means 200 at a point between the opening 237' and the opening 242' and below the bottom of the hub 252 so that the end portion 216 of the transmission lines 206 is pressed downwardly by the hub 252. Actually, as shown in FIG. 16, tip 274 of the end portion 216 is in contact with the hub 252. Similarly, the other end of the bridge member 204 meets the base 248 of the cable seizure means 202 at a point between the opening 237' and the opening 242' and below the bottom of the hub 252 so that the end 218 of the transmission line 206 is pressed downwardly by the hub 252.
In view of the fact that metal cylindrical structure 220, 252, 254 of the cable seizure means 202 is permanently connected to the conductor 62 that carries RF and AC power from the compartment 4' to the compartment 6', no diametric passageway through the hub 252 is required, but one could be present. Therefore, as shown in FIG. 16, the metal cylindrical structure 222, 252, 254 of the cable seizure means 202 does not have a diametrical passageway. A ferrule 264 that is threaded into an opening 266 such as used for the thumbscrew 258 is soldered to the conductor 62 as indicated.
FIG. 17A illustrates the closed portion of the switch formed by an annular ridge 276 between the hub 252 of the metal cylindrical structure 220, 252, 254 of the cable seizure means 200 and the end 216 of the transmission line 206 when the compartment 4' is open so that the cam 224 merely sits on the end 216. But, when the compartment 4' is closed by the cover 10, the cam 224 is pushed downward so as to force the end 216 of the transmission line 206 out of contact with the ridge of the hub 252 as shown in FIG. 17B.
Reference is again made to the exploded view of FIG. 16 for a more detailed description of the preferred integral cable seizure structure of this invention. Since the interfitting of parts for the cable seizure means 200 and 202 are the same, only the cable seizure means 200 need be described. After a ferrule 268 is inserted into the lower hollow cylinder 254 of the metal cylindrical structure 220, 252, 254, the structure is mounted on the base 248 so that the lower cylinder 254 extends into a partial cylinder 270 of slightly larger diameter to permit the structure to rotate. Note that the ferrule 268 provides for frictionally engaging an associated post 138 or 142, respectively. The ferrule 268 being composed of an electrically conductive spring material, maintains a dependable electrical contact therebetween. An axial slit 272 is provided in the upper portion of the cylinder 270 so as to permit the tip 274 of the transmission line 206 to lie under an annular ridge 276 formed by the hub 252 and the lower cylinder 254 of the cylindrical metal structure 220, 252, 254. In order to provide a close fit, an arc 278 is formed in the tip 274 that has the same radius as the lower cylinder 254. Note that the end portion 216 of the transmission line 206 is bent upwardly so that the tip 274 is initially located just above the top of the axial slit 272.
The cover 234 is lowered so that the upper cylindrical portion 220 of the metal cylindrical structure 220, 252, 254 passes through opening 246 and the openings 242 and 238 fit over the projections 242' and 238'. The cam 224 passes through the opening 225. At some point, the annular ridge 276 of the metal cylindrical structure 220, 252, 254 engages the tip 274 of the transmission line 206 and forces it downward so that the transmission line 206 acts as a tensioned spring. Finally, the annular ridge 276 strikes the top 278 of the partial cylinder 270. At this point the bolt 236 is passed through the opening 237 in the cover 234 and the like opening 237' in the base 248 and screwed into threads 280 in a riser 283. The base 248 is oriented so that the post 244 on a riser 282 passes into the projection 242' and the post 240 on a riser 284 passes into the projection 238'. Note that risers 282, 283 and 284 are in the form of posts mounted on the bottom 5 of the compartment 4'.
The foregoing description also applies to the assembly of the cable seizure means 202.
Although various embodiments of the invention have been shown and described in detail herein, they are not meant to be limiting. Those of skill in the art may recognize certain modifications to these embodiments, which modifications are meant to be covered by the spirit and scope of the appended claims. | A multi-tap 2 has two compartments 4,6, the first including input ports 46,48 for conducting RF signals (RF) and AC power (AC), a microstrip 206 for conducting the RF and AC from input ports 46,48 to a conductor 62 passing through a passageway 64 between compartments 4,6 for passing the RF and AC to the microstrip 206 in the compartment 6. The latter microstrip 206 conducts the RF and AC to output ports 78,82 at an end of the compartment 6 in a first operating configuration. In a second operating configuration, a wire 80 conducts RF and AC away from the output ports 78,82 to a microstrip 90 for conducting the RF and AC to a wire 94 passing through a passageway 96 between compartments 4,6 for further conducting the RF and AC to a microstrip 102 in compartment 4 to divert the RF and AC to alternative ouput ports 84,86 of compartment 4. Each microstrip 206 consists of resilient metal strips, and includes upwardly biased ends 216,218 which press against ridges 276 of conductor seizure cylinders 220,222, respectively, for insuring electrical circuit continuity when covers 10,12 are not in place on compartments 4,6, respectively. When covers 10,12 are in place thereon, conductive post pairs 138 and 142, and 128 and 132, respectively enter openings in cylinders 220,222, respectively, to reroute signals through circuit paths 130,140, respectively, and slidable cams 224,226 are activated by the covers 10,12 to break the electrical connection between the cylinders 220,222, and microstrips 206. | 7 |
BACKGROUND OF THE INVENTION
This invention relates generally to variable tone electric guitars and more particularly, but not by way of limitation, to an improved switching system for interchanging the selection and combination of pickup outputs to provide a wide variety of output sounds.
There are two general electric guitar sounds prevalent in the music industry today: the Gibson tonality and the Fender tonality. The Gibson tonality, such as exemplified in the LES PAUL guitar, is obtained from either or both of two dual coil hum-canceling pickups referred to herein as humbucker pickups. The Fender tonality, such as exemplified in the STRATOCASTER or TELECASTER guitars, is obtained from selected combinations of three single coil pickups.
A switching system by which either a Gibson tonality or a Fender tonality can be obtained from a single electric guitar is disclosed in U.S. Pat. No. 5,136,918 to Riboloff, which patent is incorporated herein by reference. The preferred embodiment system of the Riboloff patent uses two dual coil humbucker pickups and one single coil pickup and switching devices to allow a player to select one of at least three Gibson tonalities associated with the LES PAUL guitar or one of five Fender tonalities associated with the STRATOCASTER guitar.
SUMMARY OF THE INVENTION
The present invention is a modification of the system disclosed in the aforementioned Riboloff patent. The present invention makes additional tonalities available to the player, and the present invention makes independent pole-terminal connections from one discrete terminal to another.
The present invention provides a guitar pickup system, comprising: a dual coil bridge humbucker pickup; an intermediate pickup; a dual coil fingerboard humbucker pickup; first switch means for selecting a desired pickup configuration and thereby selecting a desired tonality signal, which first switch means includes a four pole, five position switch connected to the bridge humbucker pickup, the intermediate pickup and the fingerboard humbucker pickup so that any of a first set of five tonality signals is selected through first and second poles of the first switch means and so that any of a second set of five tonality signals is selected through third and fourth poles of the first switch means; and second switch means for connecting to an output of the second switch means either the tonality signal selected through the first and second poles of the first switch means or the tonality signal selected through the third and fourth poles of the first switch means.
Therefore, from the foregoing, it is a general object of the present invention to provide a novel and improved guitar pickup switching system. Other and further objects, features and advantages of the present invention will be readily apparent to those skilled in the art when the following description of the preferred embodiment is read in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a plan view of a guitar body showing the layout of three pickups used in the system of the present invention.
FIG. 2 is a schematic diagram of the preferred embodiment guitar switching system of the present invention.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
U.S. Pat. No. 5,136,918 to Riboloff is incorporated herein by reference.
Referring to FIG. 1, which is the same in both the present disclosure and the Riboloff '918 patent, a guitar 10 is shown with a portion of a neck 12 secured to a main body 14. The guitar 10 includes guitar strings 16 as secured to a bridge 18 and tuning screws (not shown) as known in the art.
Three pickups are arrayed beneath strings 16 and secured to a face 20 of the main body 14 in conventional manner. A treble dual coil humbucker pickup 22 (having coils 22a, 22b as shown in FIG. 2) is secured transversely beneath strings 16 and close to the bridge 18, a position known as the "bridge pickup." In similar manner, a rhythm dual coil humbucker pickup 24 (having coils 24a, 24b as shown in FIG. 2) is secured in spaced, parallel relationship closely adjacent an end 26 of the fingerboard 12, and this type of pickup is known as the "fingerboard pickup." A single coil intermediate or middle pickup 28 is secured intermediate the positions of the dual coil pickups 22, 24, but a humbucker pickup (or functionally at least one coil thereof) can also be utilized in the center position.
To obtain from the aforementioned pickups the tonalities made available by the present invention, the present invention further includes switch mechanisms that will typically be located in or near an area 30 of the face 20 of the main body 14 of the guitar 10. The switch mechanisms and their connections to the pickups 22, 24, 28 for the preferred embodiment are shown in FIG. 2.
A switch 32 is used for selecting a desired pickup configuration and thereby selecting a desired tonality signal. The switch 32 of the preferred embodiment is a four pole, five position switch connected to the bridge humbucker pickup 22, the intermediate pickup 28 and the fingerboard humbucker pickup 24 so that any of a first set of five tonality signals is selected through first and second poles 34, 36 of the switch 32 and so that any of a second set of five tonality signals is selected through third and fourth poles 38, 40 of the switch 32.
The switch 32 has a first set 100 of first through fifth terminals 102, 104, 106, 108, 110. The first terminal 102, the second terminal 104 and the fourth terminal 108 are connected to an end of the bridge humbucker pickup 22 opposite the end of the pickup connected to electrical ground as shown in FIG. 2. That is, these switch terminals are connected in common with the end of the coil 22b not connected to the coil 22a. The fifth terminal 110 is connected in between the dual coils of the bridge humbucker pickup 22 (i.e., to the junction of the coils 22a, 22b). The third terminal 106 is unconnected or open.
The switch 32 has a second set 200 of first through fifth terminals 202, 204, 206, 208, 210. The second and third terminals 204, 206 are connected to an end of the fingerboard humbucker pickup 24 opposite the end thereof connected to electrical ground. In particular, the terminals 204, 206 are connected to the end of the coil 24b opposite the end connected to the coil 24a as shown in FIG. 2. The fourth terminal 208 is connected to the intermediate pickup 28 opposite the end of that pickup which is connected to electrical ground. The fifth terminal 210 is connected in between the dual coils of the fingerboard humbucker pickup 24 (i.e., to the junction of the coils 24a, 24b). The first terminal 202 is unconnected or open.
The switch 32 has a third set 300 of first through fifth terminals 302, 304, 306, 308, 310. The first and second terminals 302, 304 are connected in between the dual coils 22a, 22b of the bridge humbucker pickup 22 (i.e., to the junction between these two coils). The fourth and fifth terminals 308, 310 are connected in between the dual coils 24a, 24b of the fingerboard humbucker pickup 24 (i.e., to the junction between these two coils). The third terminal 306 is unconnected or open.
The switch 32 has a fourth set 400 of first through fifth terminals 402, 404, 406, 408, 410. The second terminal 404, the third terminal 406 and the fourth terminal 408 are connected to the intermediate pickup 28 opposite the end thereof connected to electrical ground. The first terminal 402 and the fifth terminal 410 are unconnected or open.
The switch 32 further includes: a connector 112 for connecting a selected terminal of the first set 100 to the pole 34; a connector 212 for connecting a selected terminal of the second set 200 to the pole 36; a connector 312 for connecting a selected terminal of the third set 300 to the pole 38; and a connector 412 for connecting a selected terminal of the fourth set 400 to the pole 40. The switch 32 also includes means for synchronously operating the connectors 112, 212, 312, 412 so that the corresponding terminal of each set of terminals is connected to its respective pole at the same time. In the preferred embodiment, this is implemented by mechanically ganging four wiper arms implementing the connectors 112, 212, 312, 412 as represented in FIG. 2. The end of a single crankshaft to which the wiper arms are connected protrudes from the face 20 of the guitar's main body 14 to allow the player to rotate through the five positions of the switch 32 and simultaneously connect each wiper arm to the same respective terminal of the respective set (e.g., connector 112 to terminal 102, connector 212 to terminal 202, connector 312 to terminal 302, and connector 412 to terminal 402).
In a particular implementation, the switch 32 is implemented with a commercially available mechanical four pole, five position rotary switch from Standard Griggsby, wherein each terminal of the sets 100, 200, 300, 400 is separate and distinct and the respective connector 112, 212, 312, 412 makes contact with only a single terminal of its respective set at any one time, thereby providing a simple, positive connection at each selected position. It is contemplated, however, that other types of switches can be used, whether mechanical or non-mechanical (e.g., a non-mechanical switch such as a solid state switch providing the same functions as described above).
The present invention also comprises a switch 42 for connecting to its output 43 either the tonality signal selected through the poles 34, 36 of the switch 32 or the tonality signal selected through the poles 38, 40 of the switch 32. The switch 42 comprises: a terminal 44 connected to the pole 34 of the switch 32; a terminal 46 connected to the pole 36 of the switch 32; a terminal 48 connected to the pole 38 of the switch 32; a terminal 50 connected to the pole 40 of the switch 32; and means for selectably connecting either both terminals 44, 46 to the output of the switch 42 or both terminals 48, 50 to the output of the switch 42. Such means is illustrated in FIG. 2 by ganged, electrically connected wiper arms 52, 54 movable between position A where they contact terminals 44, 46, respectively, and position B where they contact terminals 50, 48, respectively. Particular implementations of the switch 42 include a mechanical toggle switch or a push-pull potentiometer switch, but it is contemplated that other implementations can be used.
With the switch 42 in position or mode A, multiple electrical signals provided when more than one pickup is selected through connectors 112, 212 are combined into one tonality signal because of the common communication of the electrical signals to the single output 43 of the switch 42. The same applies when the switch is in position or mode B with regard to more than one pickup being selected through connectors 312, 412. Of course, if only one pickup is selected, its electrical signal is communicated to the output 43 when the switch 42 is in the appropriate mode. The output signal from the switch 42 is communicated through an output jack 56 to which an amplifier (not shown) can be connected as known in the art. The jack 56 is shown in FIG. 2 connected to the output of the switch 42 through a resistor-capacitor network of known type.
With the switch 42 in position A, the following selections are made by operating the switch 32 of the preferred embodiment:
______________________________________Position Selection______________________________________102/202 Bridge pickup 22, both coils104/204 Pickups 22 and 24, four coils106/206 Fingerboard pickup 24, both coils108/208 Pickups 22 and 28, three coils110/210 Pickups 22 and 24 split, two coils______________________________________
The first three positions referred to in the above table are the same as the first three positions for mode A in the Riboloff '918 patent and produce a Gibson tonality of the type particularly identified with the LES PAUL guitar. The fourth position referred to in the above table provides a sound different from those specifically referenced in the Riboloff patent and different from the conventional Gibson and Fender sounds. The fifth position referred to in the above table produces a Fender tonality of the type particularly identified with the TELECASTER guitar.
With the switch 42 in position B, the following selections are made by operating the switch 32:
______________________________________Position Selection______________________________________302/402 Bridge pickup 22 split, one coil304/404 Pickup 22 split and pickup 28, two coils306/406 Intermediate pickup 28, one coil308/408 Pickup 24 split and pickup 28, two coils310/410 Fingerboard pickup 24 split, one coil______________________________________
Each of these selections corresponds to the selections that can be made during the mode B operation disclosed in the Riboloff '918 patent. Each of these selections produces a sound characteristic of the Fender STRATOCASTER guitar (the sounds from the first and fifth positions are also associated with the TELECASTER guitar).
With the above-described embodiment, any one of ten tonalities can be selected through the simple procedure of selecting mode A or B via the switch 42 and the specific tonality via the switch 32.
Thus, the present invention is well adapted to carry out the objects and attain the ends and advantages mentioned above as well as those inherent therein. While a preferred embodiment of the invention has been described for the purpose of this disclosure, changes in the construction and arrangement of parts can be made by those skilled in the art, which changes are encompassed within the spirit of this invention as defined by the appended claims. | A switching system for an electric guitar using bridge and fingerboard humbucker pickups and an intermediate pickup provides for ready selection of distinct groups of Gibson tonalities and Fender tonalities. A four pole, five position switch for tone selection provides one-of-ten tonality selection in conjunction with a dual pole, double throw switch. | 6 |
BRIEF DESCRIPTION OF THE INVENTION
The invention relates to steel making by converter. In the prior art with respect to a converter of top-blowing of pure oxygen, a steel bath is agitated by O 2 -jet blown above the molten surface and bubbles of CO generated in the bath, and reaction is progressed. However, in a case of the large scaled converter, the O 2 -jet cannot reach to a deep part of the bath and the molten steel thereabout is stagnated so that the reaction is delayed and non-uniform dispersion is created.
As countermeasures improving these disadvantages, there is Q-BOP Process, in which oxygen is blown from the bottom of the converter and at the same time the natural gas (hydrocarbon) should be much blown for cooling oxygen. Therefore, hydrogen in steel inevitably increases and the molten steel be subjected to degassing treatment in a post process. Further, it is necessary to much blow N 2 gas or the like such that the tuyere is not clogged during sampling or pouring the steel, but N 2 spoils the quality of the steel. In addition, while supplying N 2 , fine dust is considerably blown disadvantageously.
The present invention has been realized in view of these circumstances, in which the steel making comprises blowing oxygen onto the surface of the molten steel held in the converter and blowing agitating gases of 1/3 to 1/3000 of the amount of of the oxygen thereinto from tuyeres provided at bottom of the converter, which number from 1 to 30 and are from 2 to 30 mmφ in inside diameter, thereby to effectively agitate the molten steel and make blowing reaction stabilized for purposes of increasing production and improving quality of the steel.
According to the invention, the pure oxygen is blown via a lance onto the surface of the molten steel and at the same time the agitating gas is blown from the tuyeres provided at the bottom of the converter. The agitating gases may be various, and desirous are such inert gases as CO 2 , CO, Ar, N 2 or LD gas. If CO 2 gas is used, the reaction of "CO 2 →C+O", whereby the tuyere is protectively cooled, and since the volume is doubled, the agitating effect is increased and this effect serves to decrease the fundamental unit of O 2 as an oxidizing agent. If LD gas is used, it may be circulated in use with economical merit. The tuyere is from 2 to 30 mmφ in inside diameter. From 1 to 30 tuyeres are used to blow the agitating gas in the amount from 1/3 to 1/3000 of the amount of the top-blowing oxygen.
The above mentioned outlines the present invention. A reference will be made to embodiment according to the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a graph showing relation between the amount of the bottom-blowing gas and the agitating effect,
FIG. 2 is a graph showing relation between the number of the tuyeres and the agitating effect,
FIG. 3 is a graph showing relation between the diameter of the nozzle and the amount of the bottom-blowing gas,
FIG. 4 is an explanatory view showing one embodiment of this invention, and
FIG. 5 is an explanatory view showing an embodiment of circulating in use LD gas as the agitating gas.
DETAILED DESCRIPTION OF THE INVENTION
In reference to the attached drawings, FIG. 1 is a graph showing the relation between the amount of the bottom-blowing gas and the agitating effect when the amount of the top-blowing oxygen is 60000 Nm 3 /h. It is apparent from this graph that the bottom-blowing of more than 20 Nm 3 /h is required for providing the agitating effect of more than 0.3. In this point, the agitating effect is almost saturated with 20000 Nm 3 /h. Therefore, the upper limit of the amount of the bottom-blowing gas is determined as 20,000 Nm 3 /h/60,000 Nm 3 /h=1/3, and the lower limit is determined as 20 Nm 3 /h/60,000 Nm 3 /h=1/3000.
FIG. 2 is a graph showing the relation between the number of the tuyeres and the agitating effect. If the tuyeres are too much prepared, bubbles of the blown gas boil up over the molten surface, and the bath and the bubbles only exchange, and the bath does not circulate and the agitation is not effected. Therefore, in the invention, the upper limit for accomplishing the agitating effect of 30% is 30 tuyeres and the lower limit therefor is one tuyere. It is preferable to place the tuyeres nearly a center of the bottom of the converter, and in such a way the bath swells nearly the center and flows from the center to the periphery to increase the agitating effec. With respect to the inside diameter of the tuyere, it should be determined in dependence on the amount of the bottom-blown gas and the number of the tuyeres used. As shown in FIG. 3, if it is less than 2 mm, the required amount of the gas is not obtained, and if it exceeds 30 mm, such amount gas is obtained where the agitation reaches the saturation. Therefore, the lower limit is 2 mm and the upper limit is 30 mm.
FIG. 4 is an explanatory view of an example to which the inventive process is actually applied, in which the numeral 1 denotes the converter, 2 is a lance, 3 shows the molten steel, and 4 is a pipe provided in superimposed brick layer within the converter, one end of which is elongated outside from the vicinity of a mouth of the converter and the other end of which is branched to the tuyeres 5. The tuyere 5 does not need to be a double structure, but it is of a single structure. The pipe 4 may be arranged between an iron shell and the brick of the converter 1, or may be taken out externally through a hole to be formed in the iron shell at the bottom of the converter, instead of elongating from the vicinity of the converter mouth. The pipe 4 communicates with sources of CO 2 , Ar, N 2 or the air. The numeral 6 shows a holder of deoxidizing agent.
A reference will be made to the actual operation. When supplying scraps, the air or N 2 gas of 2 to 10 Kg/cm 2 is blown from the tuyeres. When pouring the molten metal, N 2 or CO 2 is blown from the bottom for avoiding air pollution. After completing supply of the scraps and the molten metal, the converter 1 is erected and the pure oxygen is jetted from the top-blowing lance 2 as it is lowered, and the burnt lime is thrown into the converter. The solvent and the fluorite are added before and after throwing of the burnt lime. The lowered lance 2 is maintained at determined height above the molten surface and starts the blowing, and at the same time the bottom-blowing is changed to CO 2 for avoiding the bath pollution owing to N 2 . By this bottom-blowing CO 2 gas the agitation of the bath is accelerated. Especially, the agitating effect is remarkable in the de-phosphorization and the de-carburization from beginning of the blowing to the middle and at the peak. In a case of such a system recovering the de-carburization generating gas, the blowing of CO 2 between the middle of the blowing and the end dilutes CO generating gas, and therefore the bottom-blowing is changed to Ar gas. When it is confirmed by an appropriate means that the component of the molten bath becomes desired, the converter 1 is tilted to the horizontal level to carrying out sampling (measuring the temperature, T.P sampling). If the tuyeres 5 are provided at the center of the bottom of the converter, the blowing pressure is, while sampling, decreased, or may be stopped since the nozzle at the bottom is exposed. On the other hand, if the tuyeres are provided over the bottom, the bottom-blowing gas prevails, when tilting the converter, toward the exposed, non loaded part, and so it is preferable to section the bottom of the converter.
After sampling, the converter is again erected for preparation of pouring the steel. At pouring, the tilting angle is changed in response to the pouring amount at stage between the pouring start and the pouring completion, and then if the tuyere is exposed from the steel bath, the bottom-blowing gas may be stopped.
After completion of pouring the steel, the bottom-blowing gas is changed to air or CO 2 . The air removes advantageously clogging of the tuyere. During exhausting the slag, the air or CO 2 is blown, and after this exhaustion, a next preparation is to supply main raw materials. In this waiting time, the air or N 2 is blown from the converter bottom to avoid clogging for preparation of supplying scraps. Thus, one cycle ends, and hereafter the above operations are repeated.
With respect to high carbon steel, special steel and the like, it is possible to use particles of CaF 2 , C and others in mixture of the blown gas from the tuyeres 5. After completion of blowing, alloy iron is appropriately blown from a hopper at the top of the converter to fully agitate the bath by the bottom-blowing gas for providing melting and reaction of the alloy iron in the converter and keeping the temperatures of the steel bath constant. It is possible to carry out the sampling and measure the temperature after making uniform the contents in the converter. The particle to be blown are not limited to soda ash only, but it is possible to add soda of alkali group and alkali earths or metals of potassium and lithium, and other compound substances.
FIG. 5 shows an example circulating in use LD gas as the agitating gas. LD gas from the converter 1 is fed to a venturi 10, and LD gas is removed from dusts and cooled there, and it is sent to a tank 12 through a blower 11 and is stored there. LD gas within the tank 12 is timely fed to the tuyeres 5 by the blower 17 for agitation and it is again circulated from the top of the converter 1. Thus, LD gas is very ecomonical. In FIG. 5 the numeral 13 is an open-close valve, 14 and 15 designate valves of controlling the flowing pressure, and 16 is a tank for other inert gases.
As the agitating gas, a non oxidizing gas is preferable as mentioned above, and in general the inert gas such as Ar or N 2 , or CO 2 are employed. However, these gases are high in production cost, since a generating apparatus is expensive, and further it takes transporting cost for these gases to be carried from the producing field by the truck or via the pipe, and its amount is restricted. In these circumstances, the present invention recommends usage of LD gas as the agitating gas. LD gas generated within the converter can be used in circulation, and by using LD gas as the agitating gas, it is possible to keep the cost down and heighten the efficiency.
One example of the component of LD gas used in the invention showed 74.4% CO, 3.1% CO 2 , 20.3% N 2 , 2.0% H 2 and 0.2% O 2 , and the heating was 2350 Kcal/Nm 3 and the circulation was 97 Nm 3 /t.
If LD gas is used, the other inert gases are not required or may be decreased in amount. Besides, CO% of LD gas itself increases and the heating also increases.
A next reference will be made to an example according to the present invention.
EXAMPLE
15 tuyeres were provided. Each had a single structure made of stainless steel pipe having a 4.2 mm inside diameter at the bottom of the converter. At the beginning the air was blown into the converter at a pressure of 4 Kg/cm 3 while the scraps of 10% of the total supply were supplied. After supplying the scrap, the blowing gas was changed to CO 2 . The pressure of blowing CO 2 was 4 Kg/cm 3 and at this stage the hot metal of 90% of the total supply was supplied into the converter. This hot metal was at the temperature of 1350° C., and the composition thereof was as shown in the table. After supplying the hot metal, pure oxygen of 14 Kg/cm 2 pressure was jetted through the top-blowing lance. The top-blowing oxygen was consumed at a rate of 48 Nm 3 /t during blowing, while the botton-blowing CO 2 was consumed at a rate of 0.5 Nm 3 /t. At the ending of blowing, the bottom-blowing gas was changed to Ar and blown at a pressure of 4 Kg/cm 2 . The temperature of the hot metal at ending was 1630° C., and the composition was 0.05% C, 0.20% Mn, 0.015% P, 0.021% S, 450 ppmO 2 , 10 ppmN 2 , 2.0 ppmH 2 . The table shows the comparison between the instant inventive process, Q-BOP Process and LD Process. Since Q-BOP Process blows LP gas as the cooling gas, H 2 content in the steel bath is as high as 4.6 ppm, while in the invention H 2 is as low as 2.0 ppm. Further, the good ingot is yielded 93.1% in LD Process, while in the invention it is 94.6% near to Q-BOP Process.
As mentioned above, the present invention is incorporated with the merits of the top-blowing process and the bottom-blowing process, and thus this invention has the remarkable excellence of increasing the yield and improving the quality of the steel.
__________________________________________________________________________INVENTIVE PROCESS__________________________________________________________________________Diameter (mm) of tuyure 4.20Type of tuyure Single stainless pipeUsing number of tuyures 15OperationHot metal ratio 90%Composition (%) of hot metal C Si Mn P S 4.50 0.40 0.50 0.110 0.030Temperature of hot metal 1350° C.Up-blow O.sub.2 48Nm.sup.3 /tBottom-blow O.sub.2 --Bottom-blow Gas CO.sub.2 : 0.5Nm.sup.3 /tBottom-blow Ar 0.2Nm.sup.3 /tBottom-blow N.sub.2 --Baked lime 50Kg/tScheelite 1.5Kg/tMill scale and/or iron ore 60Kg/tResultsComposition (%) at end point C Mn P S O N H 0.05 0.20 0.015 0.021 450ppm 10ppm 2.0ppmComposition (%) of slag T.Fe: 15 CaO: 45 SiO.sub.2 : 13Temperature at end point 1630° C.Yield of ingot 94.6%Consumption of alloy Al: 2.15Kg/t FeSi: 3Kg/t FeMn: 5.1Kg/tRecovery of LD gas 100.4Nm.sup.3 /t__________________________________________________________________________
__________________________________________________________________________Q-BOP PROCESS__________________________________________________________________________Diameter (mm) of tuyure 40 to 60φType of tuyure Double steel pipeUsing number of tuyures 18OperationHot metal ratio 90%Composition (%) of hot metal C Si Mn P S 4.50 0.40 0.50 0.110 0.030Temperature of hot metal 1350° C.Up-blow O.sub.2 --Bottom-blow O.sub.2 53.5Nm.sup.3 /tBottom-blow Gas LPG: 4Nm.sup.3 /tBottom-blow Ar 0.2Nm.sup.3 /tBottom-blow N.sub.2 20Nm.sup.3 /tBaked lime 45Kg/tScheelite 1.5Kg/tMill scale and/or iron ore 44Kg/tResultsComposition (%) at end point C Mn P S O N H 0.05 0.30 0.015 0.020 400ppm 20ppm 4.6ppmComposition (%) of slag T.Fe: 13 CaO: 48 SiO.sub.2 : 16Temperature at end point 1630° C.Yield of ingot 95.1%Composition of alloy Al: 2.0Kg/t FeSi: 4.0Kg/t FeMn: 3.4Kg/tRecovery of LD gas 116Nm.sup.3 /t__________________________________________________________________________
__________________________________________________________________________LD PROCESS__________________________________________________________________________Diameter (mm) of tuyure --Type of tuyure --Using number of tuyures --OperationHot metal ratio 90%Composition (%) of hot metal C Si Mn P S 4.50 0.40 0.50 0.110 0.030Temperature of hot metal 1350° C.Up-blow O.sub.2 50Nm.sup.3 /tBottom-blow O.sub.2 --Bottom-blow Gas --Bottom-blow Ar --Bottom-blow N.sub.2 --Baked lime 58.5Kg/tScheelite 2.0Kg/tMill scale and/or iron ore 60Kg/tResultsComposition (%) at end point C Mn P S O N H 0.05 0.13 0.020 0.022 500ppm 13ppm 2.6ppmComposition (%) of slag T.Fe: 20 CaO: 43 SiO.sub.2 : 12Temperature at end point 1630° C.Yield of ingot 93.1%Consumption of alloy Al: 2.3Kg/t FeSi: 3Kg/t FeMn: 6.3Kg/tRecovery of LD gas 96Nm.sup.3 /t__________________________________________________________________________ | Steel making by a converter comprises blowing oxygen onto the surface of molten steel held in the converter and blowing agitating gases of 1/3 to 1/3000 of the amount of said oxygen thereinto from tuyeres provided at bottom of the converter, which number from 1 to 30 and are from 2 to 30 mmφ in inside diameter, thereby to effectively agitate the molten steel and make blowing reaction stabilized for purposes of increasing production and improving quality of the steel. | 2 |
Latin name of the genus and species: The mandarin cultivar of this invention is botanically identified as Citrus reticulata.
Variety denomination: The variety denomination is ‘KinnowLS’.
BACKGROUND OF THE INVENTION
‘KinnowLS’ is a mandarin selection developed at Riverside, Calif. and derived from an irradiated bud of the diploid mandarin cultivar ‘Kinnow’ (unpatented), a mid-to-late season maturing variety. ‘Kinnow’ is a hybrid of two Citrus cultivars, ‘King’ (unpatented, Citrus reticulata ‘Blanco’) and ‘Willowleaf’ (unpatented, Citrus reticulata ‘Blanco’), which was first developed by H. B. Frost in Riverside, Calif. After evaluation, the ‘Kinnow’ was released as a new variety for commercial cultivation in 1935.
Irradiation of budwood from registered ‘Kinnow’ trees in Exeter, Calif., was accomplished in June of 1997 in Riverside, Calif. Specifically, irradiation of 150 buds of ‘Kinnow’ mandarin was accomplished using 40 Gray units of gamma irradiation from a Cobalt-60 irradiation source. Buds from this irradiation were propagated onto Carrizo rootstocks in a greenhouse in Exeter, Calif. where they were grown to field-plantable-sized trees. Out of these irradiations, a total of 73 trees were obtained. This low yield of trees is typical because the radiation kills many of the buds. These trees were then planted in May 1998 in Exeter, Calif. Fruit production and evaluation began in 2001. One selection from this irradiated population (propagated on Carrizo rootstock) distinguished itself from the others in having tree growth typical of ‘Kinnow’ mandarin, very low seed counts in comparison to the original ‘Kinnow’ cultivar, and excellent fruit quality and normal fruit production characteristic of the ‘Kinnow’ parent. After two seasons of fruiting, this selection was given the name ‘Kinnow IR5’ and selected for further trials. In January 2003, buds of this selection were taken and propagated onto Carrizo and C35 citrange rootstock for field trials. In June of 2004, 72 trees, produced in Exeter, Calif., were planted at six sites (twelve trees at each site): Arvin, Irvine, Lindcove, Thermal, Riverside, and Woodlake, Calif. All trials were propagated equally on Carrizo and C35 citrange rootstocks. All trials were in mixed-plantings with other cultivars, including seedy cultivars with high pollen viability. Fruit production of these propagated trees commenced in 2006 (a few trees at each site) and 2007 (all trees at all sites). In October 2008, budwood from the selected tree was sent to Exeter, Calif. for evaluation of disease status and, as needed, elimination of viruses and other pathogens. Six trees were then established as disease-free ‘mother’ trees in a greenhouse in Exeter, Calif. The properties of ‘KinnowLS’ were found to be true to type and transmissible by asexual reproduction in comparing these plantings with the original ‘KinnowLS’ selection.
BRIEF SUMMARY OF THE INVENTION
‘KinnowLS’ is a mid-season maturing diploid mandarin that combines large-sized fruit of excellent quality and production with low seed content even in mixed plantings. It may be successful in the mid-to-late season marketing window that currently has few low-seeded, high quality cultivars.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows fruit of ‘KinnowLS’ taken at Riverside in February.
FIG. 2 shows a side-by-side comparison of (left) ‘KinnowLS’ and (right) ‘Kinnow’.
FIG. 3 shows the eleven-year old mother tree on Carrizo citrange rootstock.
FIG. 4 shows a three-year old ‘KinnowLS’ tree in Exeter, Calif.
FIG. 5 shows the bud union of ‘KinnowLS’ on ‘Carrizo’ citrange rootstock, eleven-years old.
FIG. 6 shows fruit clusters on a three-year old ‘KinnowLS’ tree in Exeter, Calif. in the month of February.
FIG. 7 shows leaves of ‘KinnowLS’.
FIG. 8 shows open and closed flowers of ‘KinnowLS’.
DETAILED DESCRIPTION OF THE INVENTION
‘KinnowLS’ is a mandarin selection developed at Riverside and Exeter, Calif. by mutation breeding of the mandarin cultivar ‘Kinnow’, for which harvest is typically begun from mid-January to mid-February, depending on location. Evaluation of ‘KinnowLS’ began on the original tree at Exeter, Calif. in 2001 and has continued annually until the present. ‘KinnowLS’ has been asexually reproduced by grafting (budding), using the standard T-bud method generally used to propagate Citrus in California. Asexual propagation of the selected tree was first accomplished in January 2003 at Exeter, Calif. to produce 72 trial trees on Carrizo and C35 rootstocks.
‘KinnowLS’ distinguishes itself by being low seeded (2-3 seeds/fruit) in all situations of cross-pollination, while ‘Kinnow’ has 15-30 seeds per fruit in cross-pollinated situations. At Riverside, Calif. ‘KinnowLS’ matures in winter (mid-January) and holds its fruit quality characteristics through April. Fruit size is large for mandarins, classed as Jumbo by State of California standards and size 21 for industry packing standards. Fruit are oblate in shape with an orange rind color and a very smooth rind texture. Flesh is deep orange in color and finely-textured. Fruit are easy to peel and juicy, with a rich, sweet and distinctive flavor when mature. Tree growth habit is vertical and vigorous, producing a large and rather dense upright crown with excellent production commencing in the third year after planting. ‘KinnowLS’ is well adapted to growing in all California climate zones normally associated with Citrus , including desert regions, because the fruit, which matures during January through April at most locations, does well in hot climates where it matures in December. Alternate bearing can be a problem in trees that are not culturally managed to reduce this tendency.
‘KinnowLS’ mandarin can be grown according to accepted cultural practices for larger, more vigorous mandarin varieties, including planting densities of 180-250 trees per acre, normal fertilization and pest control practices, and the use of standard rootstocks for mandarins. Other rootstocks adapted to more marginal growing conditions of salinity, high pH or very heavy soils, including the lemon types C. macrophylla , Volkameriana, and rough lemon, may be useful in those conditions but overall fruit quality would likely be affected negatively. Sour orange or mandarin type rootstocks such as Cleopatra might be more suitable in these marginal conditions since fruit quality would not be affected to the extent the lemon-type rootstocks impart.
‘KinnowLS’ is a very vigorously growing tree and therefore pruning will likely be necessary to control this vigor. Such pruning should include topping the trees to control vertical growth and selective interior pruning to enhance production and health of the tree. These pruning procedures can be applied after the second year of full fruit production and regularly thereafter.
The Royal Horticulture Society (R.H.S.) color numbering system is used herein for the color description of the rind, seed, bark, leaf, flower, flesh color and other interest of the ‘KinnowLS’ mandarin cultivar.
Comparison With Existing Mandarins
A comparison of ‘KinnowLS’ with other low-seeded late-season mandarins is provided in Table 1 below. ‘KinnowLS’ is distinctive in having a very wide climatic growing area (including very hot desert areas), excellent production (though some tendency to alternate bear), and fruit quality characteristics (large size, shape, very smooth rind texture, and very rich, sweet flavor) that may be preferred in some markets.
TABLE 1 Comparison of ‘KinnowLS’ with other late season, low-seeded mandarins. Data for Riverside, California. ‘TDE2’ ‘TDE3’ (U.S. Plant Pat. (U.S. Plant Trait ‘KinnowLS’ No. 15,461) Pat. No. 15,703) Maturity Mid-February February January-February Seeds per fruit 2.45 0.02 0.29 RHS rind color Orange 25A Orange-Red Orange-Red N30D N30C Rind texture very smooth slight pit papillate Fruit weight (g) 145 185 134 Fruit 0.81 0.78 0.85 height/width Alternate medium-high medium medium-high bearing ‘TDE4’ ‘Tango’ (U.S. Plant Pat. ‘Gold Nugget’ (U.S. Plant Trait No. 16,289) (unpatented) Pat. No. 17,863) Maturity February February-March February Seeds per fruit 0.32 <0.1 0.22 RHS rind color Orange-Red Orange 25A Orange N25A N30C Rind texture smooth bumpy smooth Fruit weight (g) 175 108 90 Fruit 0.78 0.88 0.81 height/width Alternate medium-high high medium bearing
Trees, Foliage, and Flowers
Tree size and growth characteristics of ‘KinnowLS’ have been consistent with those of ‘Kinnow’ throughout the evaluations. Growth of both the ‘Kinnow’ and ‘KinnowLS’ varieties have been quite vigorous throughout the evaluation period, producing large, vertically growing trees with dense crowns. The eleven-year-old ‘KinnowLS’ mother tree at Lindcove, Calif. on Carrizo citrange rootstock, shown in FIG. 3 , is 3.1 m high and 3.0 m wide with an upright, though beginning to spread, crown exhibiting a dense growth habit and yielding a canopy volume of 14.6 m 3 . In comparison, an eleven-year-old ‘Kinnow’ control tree has averaged 3.1 m tall and 2.9 m wide, yielding a canopy volume of 13.7 m 3 on Carrizo citrange rootstock. These trees are smaller than normal because they were in a very high density planting until surrounding trees were removed at 7 years-of-age. In the younger, multi-location trials with more typical tree spacing, five-year-old ‘KinnowLS’ trees on Carrizo rootstock have averaged 3.1 m in height and 2.9 m in diameter with canopy volumes of 13.7 m 3 . Trees on C35 rootstock averaged 3.2 m in height and 3.0 m in diameter with canopy volumes of 15.1 m 3 .
Bud unions are slightly benched, as shown in FIG. 5 , resulting in a scion circumference for the eleven-year-old ‘KinnowLS’ mother tree on Carrizo rootstock of 44.5 cm with the rootstock circumference 56.5 cm measured 38 and 18 cm above the soil level, respectively. Scion circumference for five-year-old ‘KinnowLS’ trees on Carrizo rootstock averaged 40.0 cm with the rootstock circumference averaging 50.5 cm when measured about 25 and 15 cm above the soil level, respectively. Scion circumference for five-year-old ‘KinnowLS’ trees on C35 rootstock averaged 41.0 cm with the rootstock circumference averaging 51.5 cm when measured about 25 and 15 cm above the soil level, respectively.
Leaves of ‘KinnowLS’, as shown in FIG. 7 , are moderately large for a mandarin (80.8 mm in length×25.5 mm in width), lanceolate in shape and concave in cross-section and are dark-green in color (adaxial — RHS Green 137A, abaxial — RHS Yellow-Green 146B). The leaves have an acute apex with occasional weak emargination and an acute base. Petioles are medium in length (10.1 mm) and normally lack wings. The selection further lacks thorns.
As shown in FIG. 8 , flowers of ‘KinnowLS’ are hermaphroditic, borne in clusters, medium in length, with greenish-white (RHS Green White 157D, adaxial and abaxial) petals averaging 13.1 mm in length and 6.2 mm in width, and with about 18 anthers which are yellowish in color (Yellow 13B). The five sepals are rudimentary, yellow-green (RHS Yellow Green 1D) in color and partly fused into a calyx. The free portion of the sepals averages 1.53 mm in length and 1.97 mm in width. The fused portion is about 1.0 mm in length. Pollen is yellowish in color (RHS Yellow 12B).
TABLE 2
Tree, leaf, flower and seed characteristics (for eleven-year-old tree) of
‘KinnowLS’ mandarin on Carrizo.
1.
Tree height
3.1 m
2.
Crown diameter
3.0 m
3.
Crown shape/density
Upright, spreading with age and dense
4.
Scion circumference
44.5 cm
5.
Height scion measured
38 cm
above soil surface
6.
Rootstock circumference
56.5 cm
7.
Height Carrizo rootstock
18 cm
measured above soil surface
8.
Scion circumference z
40.0 cm
9.
Rootstock circumference z
50.5 cm
10.
Scion circumference y
41.0 cm
11.
Rootstock circumference y
51.5 cm
12.
Bud-union characteristics
Slightly benched (scion diameter
(on citrange rootstock)
smaller than rootstock)
13.
Rootstock-scion compatibility
No evidence of incompatibility in
trees Carrizo citrange at 11 years old
(mother tree) or on C35 citrange at 7
years old (trial trees)
14.
Tree vigor
Vigorous
15.
Bark color
RHS Grey-Brown N199A
16.
Leaf shape
Lanceolate
17.
Leaf cross-section
Concave
18.
Leaf blade length
80.8 mm
19.
Leaf blade width
25.5 mm
20.
Leaf apex
Acute with weak emargination
21.
Leaf base
Acute
22.
Leaf margins
Very slightly crenate
23.
Leaf abaxial color
RHS Yellow-Green 146B
24.
Leaf adaxial color
RHS Green 137A
25.
Petiole length
10.1 mm ± 0.7
26.
Petiole width
1.5 mm
27.
Petiole wings
Absent
28.
Petiole color
RHS Green 137A
29.
Thorniness
Not present
30.
Inflorescence type
Clustered
31.
Flowering habit
Flowers once per year
32.
Flower structure
Complete
33.
Bud length
12.2 mm
(one day before opening)
34.
Bud width
7.5 mm
(one day before opening)
35.
Bud shape
oblong
(one day before opening)
36.
Petal number
5
37.
Sepal number
5
38.
Petal length
13.1 mm
39.
Petal width
6.2 mm
40.
Petal apex
acute
41.
Petal base
truncate
42.
Petal color (adaxial)
RHS Green-White 157D
43.
Petal color (abaxial)
RHS Green-White 157D
44.
Petal shape
elliptic
45.
Petal margin
smooth
46.
Sepal number
5
47.
Sepal color
RHS Yellow-Green 1D
48.
Sepal shape
partly fused, tips attenuate
49.
Sepal length (free portion)
1.53 mm
50.
Sepal width
1.97 mm
51.
Number of anthers
18 (range 17-20)
52.
Anther color
RHS Yellow 13B
53.
Pollen color
RHS Yellow 12B
54.
Pollen viability
Moderately low (15-25%)
z,y Bud union measurements are averages for 5-year-old trial trees on Carrizo z or C35 y measured about 10 cm above (for scion) and 10 cm below (for rootstock) budunion, generally about 15 and 25 cm above soil.
Pollen viability for ‘KinnowLS’ is moderately low (15-25% germination) in comparison to ‘Kinnow’ (˜70% germination), and pollen production in comparison to normal ‘Kinnow’ is significantly reduced. These pollen characteristics suggest that ‘KinnowLS’ will not cause appreciable seediness in adjacent varieties. Crosses of ‘KinnowLS’ pollen onto Clemenules and W. Murcott gave low fruit set (6 and 9% respectively) and fruit set from these pollinations had few seeds (average 1.8 and 2.2 seeds/fruit respectively).
Fruiting, Fruit and Production Characteristics
As shown in FIG. 1 , fruit of ‘KinnowLS’ are oblate in shape with no neck. The fruit has a rounded basal end which is flattened at the stem attachment point with a truncate (slightly depressed) distal end. The fruit is large-sized for a mandarin (classed as Jumbo by State of California standards and size 21 for industry packing standards) averaging 2.7 in (68.0 mm) in diameter and 2.2 in (55.2 mm) in height. Fruit average 0.32 lb (145 g) in weight. It has a very smooth, orange color rind and slightly conspicuous, slightly depressed oil glands. The rind is slightly adherent at maturity and relatively thin, averaging 0.1 in (2.5 mm) in thickness. Fruit peel easily. The fruit interior has a moderately fine flesh texture with 10-11 segments and is quite juicy, averaging 49% juice. Fruit from trees on Carrizo and C35 citrange rootstocks average 12.2-13.9% soluble solids and 1.26-2.09% acid in mid-January at four trial locations in California increasing in soluble solids to 13.5-15.8% with acid decreasing to 0.97-1.98% in mid-February. By mid-March juice averaged 13.3-17.0% soluble solids and 0.80-1.87% acid. Fruit generally continue to increase in soluble solids and decrease in acidity well into April and May at all trial sites. See Tables 4a-4b below for mean and standard deviation of soluble solids, acid and solids/acid ratio for ‘KinnowLS’ on various rootstocks from 2007 to 2009. The earliest recommended harvest date occurs when fruit reach average soluble solids content of at least 12% and an average acid content of less than 1.2%. This may occur as early as late November in hot desert regions (Coachella Valley of Calif.), but can be as late as early April in cool locations (Irvine, Calif.) or years (2008-9).
Based on evaluation of an average of 1500 fruit per location, fruit average 2.45 seeds per fruit in the presence of heavy cross-pollination at all locations from 2007 to 2009. Rarely, individual fruit may have 4-7 seeds. In the 2010-11 season one tree was identified with a branch on which most fruit had high seed content (more than 10 seeds/fruit). However, for 5200 fruit sampled from trail trees during 2009-10 and 2010-2011, the percentage of seedy fruit was about 0.06%. Seeds are polyembryonic. See Table 5 below for average number of seeds per fruit for ‘KinnowLS’ and ‘Kinnow’ (control trees) from 2007 to 2009. Seeds are polyembryonic, with a wrinkled surface and greyed yellow seed coat (RHS 161C). Seeds average about 140 mg in weight, with about 10% of seeds much smaller and apparently lacking developed embryos.
TABLE 3
Fruit characteristics of ‘KinnowLS’ mandarin at maturity
1.
Fruit shape
Oblate
2.
Fruit diameter
68.0 mm ± 2.8
3.
Fruit height
55.2 mm ± 2.1
4.
Aspect ratio (height/diameter)
0.81
5.
Fruit: shape of basal end
Rounded (flattened at stem)
6.
Fruit: shape of distal end
Truncate (slightly depressed)
7.
Fruit: distal end areola
Present but faint
8.
Fruit: distal end areola diameter
18.8 mm
9.
Fruit neck
Not present
10.
Style
Not persistent
11.
Rind texture
Very smooth
12.
Oil glands
Slightly conspicuous, slightly
depressed
13.
Rind Color
RHS Orange 25A
14.
Rind thickness
2.5 mm
15.
Albedo thickness
1.5 mm
16.
Albedo color
RHS Orange-White 159A
17.
Rind adherence
Medium-Low
18.
Rind separation
Slight
19.
Flesh (pulp) color
RHS Orange N25B
20.
Flesh (pulp) texture
Moderately fine
21.
Number of segments
10-11
22.
Axis: structure
Semi-solid
23.
Axis: size
Medium
24.
Navel presence
Not present
25.
# Seeds/fruit (mean)
2.45 (cross-pollinated conditions)
26.
Seed embryony
Polyembryonic
27.
Seed coat color
Greyed-Yellow 161C
28.
Seed cotyledon color
Greyed-Yellow 160C
29.
Seed inner coat color
Greyed-Brown 199D
30.
Seed weight
140 mg
31.
Seed length
12.2 mm
32.
Seed width
6.0 mm
33.
Seed thickness
4.2 mm
34.
Fruit weight
145 g
35.
% Juice
49.1%
36.
% Soluble solids (at peak maturity)
14.7%
37.
% Acid (at peak maturity)
1.18%
38.
Season of maturity
Late (January-May in Northern
Hemisphere)
39.
Fruit holding ability
Excellent (6-8 weeks)
on tree past maturity
40.
Fruit quality after storage
Very Good
(5.6° C., 30 days)
TABLE 4a
Mean of soluble solids, acid and solids/acid ratio for
‘KinnowLS’ on Carrizo and C35 citrange rootstock at
four trial sites for the 2007/8 crop year.
Tree Age
Soluble
Soluble
Dates
In 2008
Solids %
Solids %
Site
Sampled
# Trees
(yrs)
Carrrizo
C35
Riverside
Jan. 15, 2008
6
4
13.2
13.1
Riverside
Feb. 14, 2008
5
4
14.6
14.8
Riverside
Mar. 12, 2008
3
4
16.5
16.6
Lindcove
Jan. 14, 2008
6
4
13.0
12.8
Lindcove
Feb. 12, 2008
6
4
14.5
14.3
Lindcove
Mar. 13, 2008
3
4
16.4
16.9
Irvine
Jan. 16, 2008
6
4
12.2
12.3
Irvine
Feb. 15, 2008
6
4
13.9
13.5
Irvine
Mar. 11, 2008
4
4
15.1
14.6
Arvin
Jan. 15, 2008
6
4
13.6
13.1
Arvin
Feb. 13, 2008
6
4
14.8
14.4
Arvin
Mar. 14, 2008
4
4
15.7
15.6
S/A
S/A
Dates
% Acid
% Acid
Ratio
Ratio
Site
Sampled
Carrizo
C35
Carrizo
C35
Riverside
Jan. 15, 2008
1.60
1.66
8.3
7.9
Riverside
Feb. 14, 2008
1.41
1.45
10.4
10.2
Riverside
Mar. 12, 2008
1.19
1.25
13.7
13.3
Lindcove
Jan. 14, 2008
1.29
1.36
10.1
9.4
Lindcove
Feb. 12, 2008
1.20
1.26
12.1
11.3
Lindcove
Mar. 13, 2008
0.91
0.90
18.0
18.8
Irvine
Jan. 16, 2008
1.88
1.69
6.5
7.3
Irvine
Feb. 15, 2008
1.50
1.56
9.3
8.7
Irvine
Mar. 11, 2008
1.21
1.18
12.5
12.4
Arvin
Jan. 15, 2008
1.20
1.23
11.3
10.7
Arvin
Feb. 13, 2008
1.03
1.07
14.4
13.5
Arvin
Mar. 14, 2008
0.88
0.90
17.8
17.3
TABLE 4b
Mean of soluble solids, acid and solids/acid ratio for
‘KinnowLS’ on Carrizo and C35 citrange rootstock at
four trial sites for the 2008/9 crop year.
Tree Age
Soluble
Soluble
Dates
#
In 2009
Solids %
Solids %
Site
Sampled
Trees
(yrs)
Carrrizo
C35
Riverside
Jan. 15, 2009
6
5
15.6
16.5
Riverside
Feb. 4, 2009
5
5
15.8
15.8
Riverside
Feb. 25, 2009
5
5
16.2
16.5
Riverside
Mar. 16, 2009
3
5
16.9
17.0
Lindcove
Jan. 13, 2009
6
5
13.4
13.9
Lindcove
Feb. 2, 2009
6
5
13.4
14.5
Lindcove
Mar. 14, 2009
3
5
14.0
14.4
Lindcove
Apr. 1, 2009
3
5
15.6
15.5
Irvine
Jan. 7, 2009
6
5
13.7
13.9
Irvine
Jan. 26, 2009
6
5
13.5
14.3
Irvine
Feb. 24, 2009
6
5
13.4
14.6
Irvine
Mar. 16, 2009
4
5
13.4
14.7
Irvine
Mar. 30, 2009
4
5
13.4
14.9
Arvin
Jan. 14, 2009
6
5
13.3
12.3
Arvin
Feb. 3, 2009
6
5
12.6
12.1
Arvin
Mar. 14, 2009
4
5
13.3
13.4
Arvin
Apr. 1, 2009
4
5
15.3
14.1
S/A
S/A
Dates
% Acid
% Acid
Ratio
Ratio
Site
Sampled
Carrizo
C35
Carrizo
C35
Riverside
Jan. 15, 2009
2.09
2.21
7.5
7.5
Riverside
Feb. 4, 2009
1.78
1.98
8.9
8.0
Riverside
Feb. 25, 2009
1.68
1.99
9.6
8.3
Riverside
Mar. 16, 2009
1.50
1.87
11.3
9.1
Lindcove
Jan. 13, 2009
1.26
1.47
10.6
9.5
Lindcove
Feb. 2, 2009
1.18
1.17
11.4
12.4
Lindcove
Mar. 14, 2009
0.80
0.97
17.5
14.8
Lindcove
Apr. 1, 2009
0.70
0.89
22.3
17.4
Irvine
Jan. 7, 2009
1.88
2.11
7.3
6.6
Irvine
Jan. 26, 2009
1.79
2.62
7.5
5.5
Irvine
Feb. 24, 2009
1.64
1.94
8.2
7.5
Irvine
Mar. 16, 2009
1.37
1.77
9.8
8.3
Irvine
Mar. 30, 2009
1.18
1.59
11.4
9.4
Arvin
Jan. 14, 2009
1.17
1.16
11.4
10.6
Arvin
Feb. 3, 2009
0.97
1.11
13.0
10.9
Arvin
Mar. 14, 2009
0.80
0.87
16.6
15.4
Arvin
Apr. 1, 2009
0.76
0.75
20.1
18.8
TABLE 5
Seed counts (average number of seeds per fruit) for
‘KinnowLS’ and ‘Kinnow’ (control trees) at four trial
sites over two years, 2007/2008 and 2008/2009.
Tree Age
#
In 2009
Site
Selection
Trees
(yrs)
Rootstock
Riverside
‘KinnowLS’
6
5
Carrizo
Riverside
‘KinnowLS’
5
5
C35
Riverside
‘Kinnow’ control
3
5
Carrizo/C35
Lindcove
‘KinnowLS’
6
5
Carrizo
Lindcove
‘KinnowLS’
6
5
C35
Lindcove
‘Kinnow’ control
3
5
Carrizo/C35
Lindcove
‘KinnowLS’
1
11
Carrizo
(mother tree)
Irvine
‘KinnowLS’
6
5
Carrizo
Irvine
‘KinnowLS’
6
5
C35
Irvine
‘Kinnow’ control
4
5
Carrizo/C35
Arvin
‘KinnowLS’
6
5
Carrizo
Arvin
‘KinnowLS’
6
5
C35
Arvin
‘Kinnow’ control
4
5
Carrizo/C35
2007/8
2008/9
Mean Seeds/Fruit
Mean Seeds/Fruit
Site
Selection
(range/tree)
(range/tree)
Riverside
‘KinnowLS’
2.4
(1.6-3.0)
2.3
(2.1-3.0)
Riverside
‘KinnowLS’
2.2
(1.5-2.9)
2.4
(1.9-3.1)
Riverside
‘Kinnow’
18.9
(17.4-20.6)
20.8
(18.8-22.1)
control
Lindcove
‘KinnowLS’
2.8
(2.3-3.1)
2.6
(2.2-2.9)
Lindcove
‘KinnowLS’
2.4
(1.7-2.9)
2.5
(2.0-3.0)
Lindcove
‘Kinnow’
26.2
(22.1-27.5)
22.3
(19.7-23.7)
control
Lindcove
‘KinnowLS’
2.4
2.1
(mother tree)
Irvine
‘KinnowLS’
2.0
(1.7-2.8)
1.8
(0.8-2.3)
Irvine
‘KinnowLS’
1.9
(1.4-2.6)
2.4
(1.4-2.9)
Irvine
‘Kinnow’
20.6
(17.8-22.1)
18.6
(16.9-19.7)
control
Arvin
‘KinnowLS’
1.6
(0.8-1.9)
1.8
(0.9-2.2)
Arvin
‘KinnowLS’
1.4
(1.0-2.0)
1.5
(0.7-2.1)
Arvin
‘Kinnow’
22.1
(18.6-24.5)
17.9
(17.3-18.4)
control
% Fruit with
0-3 seeds
Site
Selection
(2008/9)
Riverside
‘KinnowLS’
87.3
Riverside
‘KinnowLS’
88.8
Riverside
‘Kinnow’ control
0
Lindcove
‘KinnowLS’
86.9
Lindcove
‘KinnowLS’
90.7
Lindcove
‘Kinnow’ control
0
Lindcove
‘KinnowLS’ (mother tree)
89.1
Irvine
‘KinnowLS’
86.5
Irvine
‘KinnowLS’
91.4
Irvine
‘Kinnow’ control
0
Arvin
‘KinnowLS’
91.2
Arvin
‘KinnowLS’
87.1
Arvin
‘Kinnow’ control
0
Full fruit production of ‘KinnowLS’ normally begins in the third year after planting, however trees can be precocious and set some fruit in the second year after planting. FIGS. 4 and 6 illustrate fruit production on a three-year old tree. ‘KinnowLS’, is similar to ‘Kinnow’ in reaching high production levels relatively quickly. Mean yield of five year-old trees ranged from 152-211 lb (69-96 kg) on Carrizo rootstock and 165-196 lb (75-89 kg) on C35 rootstock at the four fruiting trial sites. The original ‘KinnowLS’ mother tree at Lindcove, Calif. produced 156 lb (71 kg) in the fifth year and in years 9, 10 and 11 yielded 191, 101, 240 lb of fruit respectively, which indicates that the variety has somewhat of a tendency to alternate bearing. In this respect, it is similar to ‘Kinnow’, which can exhibit severe alternate bearing if the crop is not managed to reduce overproduction in ‘on’ years.
TABLE 6
Crop yields for ‘KinnowLS’ and ‘Kinnow’ (control trees) at three trial
sites over two years, 2007/2008 and 2008/2009
Tree Age
2007/8
#
in 2009
Mean
Site
Selection
Trees
(yrs)
Rootstock
Yield (kg)
Riverside
'KinnowLS’
6
5
Carrizo
40
Riverside
'KinnowLS’
5
5
C35
32
Riverside
'Kinnow’ control
3
5
Carrizo/C35
36
Lindcove
'KinnowLS’
6
5
Carrizo
59
Lindcove
'KinnowLS’
6
5
C35
63
Lindcove
'Kinnow’ control
3
5
Carrizo/C35
52
Lindcove
'KinnowLS’
1
11
Carrizo
46
(mother tree)
Irvine
'KinnowLS’
6
5
Carrizo
44
Irvine
'KinnowLS’
6
5
C35
47
Irvine
'Kinnow’ control
4
5
Carrizo/C35
39
Arvin
'KinnowLS’
6
5
Carrizo
70
Arvin
'KinnowLS’
6
5
C35
73
Arvin
'Kinnow’ control
4
5
Carrizo/C35
64
2007/8
2008/9
2008/9
Yield Range
Mean
Yield Range
Site
Selection
(kg)
Yield (kg)
(kg)
Riverside
'KinnowLS’
28-46
71
59-83
Riverside
'KinnowLS’
20-36
75
48-89
Riverside
'Kinnow’ control
32-39
62
51-74
Lindcove
'KinnowLS’
49-66
69
22-90
Lindcove
'KinnowLS’
54-71
78
55-87
Lindcove
'Kinnow’ control
45-58
28
17-31
Lindcove
'KinnowLS’
46
109
109
(mother tree)
Irvine
'KinnowLS’
35-50
72
33-91
Irvine
'KinnowLS’
34-55
76
53-88
Irvine
'Kinnow’ control
30-44
58
31-80
Arvin
'KinnowLS’
61-86
96
81-110
Arvin
'KinnowLS’
60-89
89
78-112
Arvin
'Kinnow’ control
55-74
91
75-105
Fruit storage trials included storage of washed but not waxed fruit at 5.6° C. for up to 30 days with fruit samples taken every 15 days for analysis. Data indicates that the storage characteristics of ‘KinnowLS’ are very good with very little measureable loss of rind quality or color, no significant loss in juice quality or deterioration in taste, and no significant indication of fungal or other disease problems over the 30 day storage period. Overall ‘KinnowLS’ can be considered to be very good in storage ability for 4-6 weeks under controlled environment storage conditions.
No susceptibilities to plant or fruit diseases, or to pests, beyond those normally associated with Citrus species, have been observed. | ‘KinnowLS’ is a mid- to late-season maturing (depending on climate) diploid mandarin that combines large-sized fruit of excellent quality and production with low seed content even in mixed plantings. It may be successful in the mid-to-late season marketing window that currently has few low-seeded, high quality cultivars. | 0 |
FIELD OF THE INVENTION
This invention relates to a needle assembly for use with a feeder for feeding molten glass to a glass forming machine. More particularly, this invention relates to a needle assembly of the foregoing type in which the position of the needle relative to the orifice of the feeder bowl that incorporates such needle may be adjusted, to control glass flow rate through the orifice, by a machine operator on the forming machine floor, without the need to climb to the level of the feeder bowl to determine the position of the needle or to change its position.
BACKGROUND OF THE INVENTION
In the manufacture of glass containers by a process that is often referred to as the flow process, molten glass flows through an orifice at the bottom of a feeder bowl, which is located at the outlet end of a molten glass conditioning forehearth, to a glass forming machine positioned beneath the feeder. In such an arrangement the feeder bowl is at an elevation which is substantially above the elevation of the floor on which the forming machine is positioned beneath the feeder bowl. The rate of flow of molten glass through the orifice of the feeder bowl must be closely controlled to control the weight of the containers being formed by the underlying forming machine, and such control is accomplished by controlling the position of a vertical elongate member, called a needle, relative to the fixed position of the feeder bowl orifice. Typically, in conventional glass container manufacturing operations each feeder bowl will have two or more flow orifices, and each such orifice will be provided with a needle whose position relative to its flow orifice during the flow process must be controlled independently of the positions of the other needles associated with the same feeder bowl. Further, it is customary to provide a mechanism for intermittently retracting each needle from its feeder bowl orifice to suspend flow through the orifice when a shearing mechanism positioned between the feeder bowl orifice and the forming machine is operating to shear the glass stream flowing from the orifice into a series of gobs, each of which is to be formed into a container by the forming machine.
The adjustment of needles in feeder bowls of the type described above, independently of the reciprocation of the needle as required to coordinate feeder bowl operation with shear mechanism operation, typically requires that a glass forming machine operator climb to the level of the feeder bowl, an area where the temperature will often inherently be uncomfortably high, to make a mechanical adjustment in the position of one or more of the feeder needles. Following this, the operator must return to the forming machine floor to weigh freshly formed containers to determine if any further adjustment in the needle position is required, and to return to the level of the feeder to make a further adjustment in the position of one or more of the needles if any of the containers are still not within applicable weight specifications, and to repeat this process until all containers are within weight specifications. Clearly, this is a tedious and unpleasant way to maintain suitable control over glass container weight, and its time-consuming nature precludes the making of needle position adjustments in as timely a manner, or as frequently, as is desirable.
Various glass melting bowl needle assemblies according to the prior art are disclosed in U.S. Pat. No. 4,581,055 (Bratton), U.S. Pat. No. 4,554,000 (Suomala et al.), and U.S. Pat. No. 4,682,998 (Ayala-Ortiz), the disclosure of each of which is incorporated by reference herein.
BRIEF DESCRIPTION OF THE INVENTION
In accordance with the present invention there is provided a needle assembly for a glass feeder bowl in which the position of each needle, within the limits of its travel and relative to the feeder bowl orifice with which it is associated, can be determined, and adjusted if and when necessary, by a forming machine operator without the need for the operator to climb to an elevation above the level of the forming machine floor. The needle adjustment mechanism of the needle assembly of this invention incorporates an electrical stepper motor for each needle to permit adjustment of the position of the needle in small steps of a predetermined magnitude for precise control of the needle position and the weight of the glass containers being formed from the glass stream that flows through the feeder bowl orifice with which the needle is associated. A pneumatic lock mechanism is provided to lock the needle in position after its adjustment to a proper position has been made, and the needle lock mechanism can be actuated by an operator at the level of the forming machine floor when it is necessary to make a further adjustment in the position of the needle.
In the preferred embodiment of the present invention the needle adjustment motors are located at the elevation of the needle adjustment mechanisms, but at a substantial distance from the needle adjustment mechanisms and therefore away from the damaging effects of the high temperatures that are prevalent in the region of the needle adjustment mechanisms to permit the motor to operate the adjustment mechanism, a novel gear box/drive shaft/needle screw connection linkage mechanism being provided between each motor and the associated needle to transmit motion of the motor to the needle. A potentiometer or other position sensing device is drivably connected to the stepper motor that drives the adjusting drive shaft to determine the relative circumferential orientation of the adjusting drive shaft, an indication of the position of the needle within the limits of its adjustment range and relative to its orifice, and to transmit a signal to a control panel on the forming machine floor to provide such information to the operator. Further, the needle adjustment assembly of the present invention can be readily disassembled and reassembled to permit rapid change of the needles and the associated feeder bowl tube through which the needles pass, and this is important in a glass container forming operation because of the need to replace all needles and tubes every several days.
A needle assembly according to the present invention lends itself quite readily to manual control of bottle weight, where the forming machine operator makes a manual adjustment of the needle position, after weighing freshly formed containers, to correct an out of weight condition in the containers. This is the preferred mode of practicing the invention in conjunction with a glass forming machine of the blow and blow type, and can also be used with a glass forming machine of the press and blow type. Alternatively, with a glass forming machine of the press and blow type, it is contemplated that the needle assembly of the present invention can be adapted to automatic weight control by using a signal from the forming machine plunger press as an indication of glass gob weight.
Accordingly, it is an object of the present invention to provide an improved glass feeder needle assembly. More particularly, it is an object of the present invention to provide a needle assembly in which the position of each needle relative to the orifice of the glass feeder bowl with which it is associated can be detected, and changed when necessary, at locations remote from the feeder bowl, for example, by a forming machine operator without the requirement that the operator climb to the level of the feeder bowl to do
For a further understanding of the present invention and the objects thereof, attention is directed to the drawing and to the following brief description thereof, to the detailed description of the preferred embodiment of the invention and to the appended claims.
BRIEF DESCRIPTION OF THE DRAWING
FIG. 1 is a schematic view of a glass feeder assembly according to the preferred embodiment of the present invention;
FIG. 2 is a fragmentary perspective view, at an enlarged scale, of a portion of the glass feeder assembly of FIG. 1;
FIG. 3 is a fragmentary perspective view, at an enlarged scale, of another portion of the glass feeder assembly of FIG. 1, some of the structure being shown in phantom;
FIG. 4 is an elevational view, partly in cross-section and at an enlarged scale, of a portion of the glass feeder assembly of FIG. 1 in conjunction with a glass feeder bowl with which the feeder assembly is intended to be used;
FIG. 5 is a fragmentary elevational view of a portion of the glass feeder assembly of the preferred embodiment of the present invention;
FIG. 6 is a fragmentary planned view of a portion of the glass feeder assembly according to the preferred embodiment of the present invention;
FIG. 7 is a fragmentary planned view of a portion of the glass feeder assembly according to the preferred embodiment of the present invention;
FIG. 8 is a fragmentary elevational view of a portion of the glass feeder assembly according to the preferred embodiment of the present invention in conjunction with a glass feeder bowl with which the feeder assembly is intended to be used;
FIG. 9 is a fragmentary elevational view, at an enlarged scale, of a portion of the glass feeder assembly of FIG. 1;
FIG. 10 is a view taken on line 10--10 of FIG. 9;
FIG. 11 is a view taken on line 11--11 of FIG. 9;
FIG. 12 is a fragmentary elevational view, at an enlarged scale, of a portion of the glass feeder assembly according to the preferred embodiment of the present invention;
FIG. 13 is a sectional view taken on line 13--13 of FIG. 12;
FIG. 14 is a sectional view taken on line 14--14 of FIG. 8;
FIG. 15 is a fragmentary elevational view, partly in cross-section and at an enlarged scale, of a portion of the glass feeder assembly according to FIG. 1;
FIG. 16 is a fragmentary elevational view, partly in cross-section and at an enlarged scale, taken at right angles to the view of FIG. 15;
FIG. 17 is cross-sectional view taken on line 17--17 of FIG. 16;
FIG. 18 is a cross-sectional view taken on line 18--18 of FIG. 16;
FIG. 19 is an elevational view, partly in cross-section and at an enlarged scale, of a portion of the glass feeder assembly of FIG. 1; and
FIG. 20 is a view taken on line 20--20 of FIG. 19.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
A glass melter needle assembly according to the preferred embodiment of the present invention is indicated generally by reference numeral 30, and comprises three like needles 32, though a greater or lesser number of such needles may be used in a given glass melter installation. Each needle 32 controls the rate of flow through an orifice of a glass melter bowl, as will hereinafter be described more fully, and is capable of being raised and lowered in small, precise increments independently of the other needles 32 by an electrical stepper motor 34. Each stepper motor 34 is positioned well away from the location of the needles 32, to avoid the damaging effects of the high temperature environment that will inherently exist in the region proximate to the location of the needles 32, as will hereinafter be explained more fully. To transmit raising and lowering torque to each needle 32 from its associated stepper motor 34, a linkage mechanism 36, comprising a generally horizontally extending member 38 and a vertically extending member 40, is provided. The electrical connections to the stepper motor 34 are by way of a roll-action feed harness 42, because the assembly 30 must be continuously reciprocated relative to a glass shearing mechanism, not shown, which is positioned below the needle assembly 30 and above a glass forming machine, also not shown, to interrupt the flow of glass to the shearing mechanism during its shearing cycle.
The needles 32, which are continuously immersed in molten glass, as will be hereinafter explained more fully, are constructed of a temperature resistant refractory material. Nevertheless, the needles 32 are subject to wear during their normal life cycle, which typically will be approximately ten days in continuous operation. This wear must be compensated for by the repositioning of each needle to maintain a predetermined glass flow rate through its associated melter orifice, as the weight of the container being formed from the glass stream flowing through such orifice is a function of the glass flow rate. Thus, a weigh station, not shown, is positioned near the container forming machine, to permit the forming machine operator to periodically weigh freshly formed glass containers to determine if they are within applicable weight specifications. Alternatively, freshly formed glass containers can be automatically weighed as they exit the glass forming machine, and it is contemplated that such a system would be beneficial in conjunction with the application of the present invention to glass forming machines of the press and blow type.
In connection with non-automated applications of the present invention, such as those intended for glass forming operations of the blow and blow type, a push button operator's control station 44 is positioned near the forming machine weigh station, to permit the operator to initiate an adjustment in the position of the needle 32 that controls the rate of glass flow through the orifice from which the out of specification container was formed. A control signal from the operator's control station 44 is transmitted to an electronic control cabinet 46, which is typically located in a control room on the forming machine floor. The control cabinet 46 controls the flow of electricity to a lock cylinder solenoid 48, after which a time delay begins to allow the needle position lock mechanism, which is indicated generally by reference numeral 50 in FIG. 1, to move to its unlocked position. A junction box 56 is provided between the control cabinet 46 and the stepper motor 34 to provide simple cable replacement with the use of quick disconnects. A timing cam 52, which is used to coordinate the timing of the reciprocation of the needle assembly 30 with the operation of its associated shearing device, is provided with a position sensor 54 to detect the proper position of the needle assembly 30 in its reciprocation cycle at which the needle lock mechanism 50 can be returned to its lock position. Upon completion of the time delay the control cabinet 46 then controls the flow of electricity to the associated stepper motor 34 permitting it to make an adjustment in the position of its associated needle 32.
Each of the stepper motors 34 is mounted on a vertical leg 58 of a generally L-shaped frame 60, the generally horizontal leg 62 of which extends towards the needles 32. The needles 32 are supported from a support member 64 which is removably and adjustably secured to the horizontal leg 62 of the frame 60, and the support member 64 is caused to reciprocate in a vertical plane, and to thereby reciprocate the frame 60, by the vertical rods 66, 68, which extend from the underside of the support member 64 to a reciprocating mechanism, indicated generally by reference numerals 70 in FIG. 5. The relative position of each needle 32 within the limits of its overall stroke, typically a distance of approximately ±1-1/2 inches (a total of 3 inches), is sensed by a potentiometer 72, which is mounted on the vertical leg 58 of the frame 60 (FIG. 2). The potentiometer 72 is driven by one of the stepper motors 34 through an endless drive 74, the member 38 of the linkage mechanism 36 being directly driven by the stepper motor 34 (FIGS. 19 and 20). The potentiometer 72, thus, produces a variable voltage signal which is indicative of the circumferential position of the horizontal member 38 that is driven through such potentiometer 72, and this voltage signal is transmitted through the feed harness 42 to the control cabinet 46, and from the control cabinet 46 to the control panel 44. An operator can use such needle position indication in conjunction with container weight information to make precise adjustments in the positions of the needles 32, and the use of stepper motors 34 to make such adjustments permits the adjustments to be made in increments as small as 1/8 turn in the output shaft of the stepper motor 34, and in an arrangement where a complete turn in the output shaft of the stepper motor 34 can translate into a position adjustment as small as 1/16 inch in the position of a needle 32.
As is shown, for example, in FIG. 4, the needles 32 of the feeder assembly 30 are used in conjunction with a feeder bowl 76 of a glass melter, otherwise not shown. The feeder bowl 76 is normally positioned at an outlet end of an elongate molten glass conditioning channel, which is usually called a forehearth. The feeder bowl 76 has an opening 78 in the bottom thereof, and a refractory tube 80 extends downwardly into the feeder bowl 76, through the molten glass therein, to nearly the level of the opening 78, the refractory tube 80 being coaxial with the opening 78 and having an inside diameter approximately equal to the maximum dimension of the opening 78. The refractory tube 80 is caused to slowly rotate relative to the feeder bowl 76, to ensure a proper mixing and temperature uniformity of the glass flowing through the opening 78, by a drive mechanism indicated generally by reference numeral 82, which may be of known construction. In any event, each of the needles 32 is positioned on the interior of the refractory tube 80 and is in alignment with an outlet orifice 84 in an orifice plate 86, which is positioned immediately below the opening 78, and each needle 32 thereby serves to limit the rate at which molten glass can flow from the feeder bowl 76 through such outlet orifice 84.
Each horizontal member 38 of the linkage mechanism 36 drives its associated vertical member 40 through a bevel gear torque transfer device 88. Each horizontal member 38 is of telescopic construction, having an outer annular member 90 connected to the potentiometer 72 and an inner member 92, which is telescopically received in the outer member 90 and is connected to the torque transfer device 88. As is shown in FIG. 10, the interior of the outer member 90 and the exterior of the inner member 92 are of similar non-circular shapes, for example, square shapes, and the inner member 92 fits snugly, but slidably, within the outer member 90 to the inner member 92 with minimum backlash. The connection between the free end of the outer member 90 and the potentiometer 72 is a universal joint 94, the free end of each outer member 90 also being releasably connected to its universal joint 94 by a cotter pin and cable assembly 96 (FIG. 19) for safety reasons, for example, to prevent the outer member 90 from falling into the feeder bowl 76. Similarly, the connection between the free end of each inner member 92 and the torque transfer device 88 to which it is connected as a universal joint 98, the free end of each inner member 92 also being releasably connected to its universal joint 98 by a cotter pin and cable assembly 100 for safety reasons, for example to prevent the inner member 92 from falling into the feeder bowl 76.
Each vertical member 40 of the linkage mechanism comprises a rod 102 which is rotatably driven by one of the torque transfer devices 88 and extends downwardly therefrom. A lowermost end of the rod 102 is non slidably received in an upper portion of a sleeve 104. The sleeve 104 has a non-circular central opening 106, and an annular member 108 with a similar non-circular exterior is slidably received in the central opening 106 and extends downwardly therefrom (FIGS. 9 and 11). The annular member 108 has a central opening 110 and the upper end of a rod 112 is received in the central opening 110 and is pinned against motion relative to the annular member 108 by a pin 114. A major portion of the rod 112 is threaded and is threadably received in a nut 116 (FIG. 15), which is fixedly suspended from the torque transfer device 88 by a spaced apart pair of plates 118. Thus, rotation of the rod 112 will cause the sleeve 126 to rise or fall relative to the plates 118.
The nut 116 has an outer sleeve 120 suspended therefrom, the outer sleeve being fixed to the nut 116 by a pair or set screws 22 and having an opposed pair of vertical slots 124 therein. An inner sleeve 126 is slidably positioned within the outer sleeve 120, and the inner sleeve 126 has an annular member 128 secured to its upper end by an opposed pair of cap screws 130. The free end of the cap screws 130 extend through the slots 124, and the opposed ends of the slots 124, thus, serve as upper and lower limits on the travel of the inner sleeve 126 within the outer sleeve 120.
The movement of the inner sleeve 126 within the outer sleeve 120 is actuated by the rotation of the rod 112, the lowermost threaded portion of which is threadably received in a nut 172 which is affixed to the annular member 128. The inner sleeve 124 has an annular extension. 132 affixed to its lowermost extremity, and the extension 132 receives an enlarged end portion 32a of the needle 32 therein, the end portion 32a engaging an annular shoulder portion 132a of the annular extension 132 to fix the position of the needle 32 relative to the inner sleeve 126. The needle 32 is removably secured in position with respect to the annular extension 132 by a set screw 134 which extends through the annular extension 132 to engage the enlarged end portion 32a of the sleeve, and the assembly of each of the vertical members 40 is stabilized by a retainer plate 136 which engages the exterior of each of the outer sleeves 120. The extension 32 is removably secured to the free end of the inner sleeve 126 by a pin 138, which extends through aligned apertures in the annular extension 132 and the inner sleeve 126, respectively. This permits a needle 32 an extension 132 to be preassembled for rapid assembly to the inner sleeve 126 when it is desired to replace a needle. Further, the inner sleeve 126 is provided with a radial shoulder 126a which will engage the free end of the extension 132 when the apertures that receive the pin 138 are in vertical alignment.
The position of the inner sleeve 126 with respect to the outer sleeve 120 is releasably locked in place when it is not desired to adjust the position of the needle 32 with respect to its orifice 84 by a set screw 140, which is threadably received in a boss 120a of the outer sleeve 120 to engage the inner sleeve 126. The set screw 140 has a head 140a, which is square or otherwise non-circular in cross-section, and the head 140a is received in a similarly shaped opening 142a in an end of an elongate member 142 (FIGS. 16 and 17). The opposed end of the elongate member 142 is slidably received in an annular member 144, and the elongate member and the annular member 144 are releasably joined to one another by a pin 146, which passes through aligned openings in the annular member 144 and the elongate member 142. The annular member 144 has a closed opposed end 144a, and the closed end 144a has a generally radial slot 144b extending partly thereto along the longitudinal central axis of the annular member 144. The generally radial slot 144b of the annular member receives an output shaft 148a of a pneumatic or hydraulic rotary motor 148, which is mounted on a fixed support structure 150, which incorporates a bearing 152 to rotatably support the annular member 144, and the output shaft 148a is of square, or other non-circular shape (FIG. 18), to impart rotary motion to the annular member 144, and thereby to the elongate member 142 and the set screw 140, when the motor 148 is driven. Thus, by controlling the operator of the motor 148, for example, by a push button at the control panel 44, it is possible to selectively lock or unlock the position of the inner sleeve 126 with respect to the outer sleeve 120, so that an adjustment in such position can not inadvertently occur at an improper time during the reciprocation of the needle assembly by the reciprocating mechanism 70 (FIG. 5).
The operation of the reciprocating mechanism 70 is powered by an electrical motor 154 which operates a conventional variable speed reducer 156 to rotate the timing cam 52. A cam follower 158 at the end of a pivoted link 160 is biased against the exterior of the timing cam 52, and the motion which is imparted to the cam follower 158 by the rotation of the timing cam 52 is imparted to an end of a rocker arm 162, which is pivoted about an axis between its opposed ends. The rocking motion of the rocker arm 162, in turn, acts to reciprocate the L-shaped frame 60 through a link 164, an end of which is pivotally joined to an opposed end of the rocker arm 162. The opposed end of the link 164 is pivotally connected to a boss 166 on the underside of the horizontal leg 62 of the L-shaped frame 60. The reciprocating motion of the L-shaped frame 60, as heretofore described, is cushioned by a pneumatic or hydraulic cylinder 168, the rod end of the cylinder 168 being pivotally connected to the boss 166 and the piston end of the cylinder 168 being pivotally connected to a fixed frame member 170.
Although the best mode contemplated by the inventors for carrying out the present invention as of the filing date hereof has been shown and described herein, it will be apparent to those skilled in the art that suitable modifications, variations, and equivalents may be made without departing from the scope of the invention, such scope being limited solely by the terms of the following claims. | A needle assembly (30) for controlling the flow of molten glass from a feeder bowl (76) through one or more orifices (84) in an orifice plate (86) beneath the feeder bowl. The needle assembly includes a vertical needle (32) for each orifice and each needle is precisely adjustable along its vertical axis by a stepper motor (34). The stepper motor for each needle is positioned remotely from the needle and drives the needle through a potentiometer (72) and a linkage mechanism (36). Each linkage mechanism includes a generally horizontally extending member (38), a vertically extending member (40), and a bevel gear drive (88) to permit the generally horizontally extending ember to drive the vertically extending member. The rotation of the potentiometer is a measure of the travel of the needle, and sends a signal of the position of the needle to an operator at the level of the forming machine floor, who can, when necessary, actuate a stepper motor to adjust the position of the needle without the need to leave the forming machine floor. | 2 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to a purifying catalyst for the exhaust gas from an internal combustion engine which deprives the exhaust gas simultaneously of the harmful components, i.e. carbon monoxide (CO), hydrocarbon (HC), and nitrogen oxides (NO x ).
2. Description of the Prior Art
In such purifying catalysts for the exhaust gas from the internal combustion engine of an automobile, for example, as are intended to effect simultaneous removal of the harmful components of the exhaust gas, i.e. CO, HC, and NO x , such platinum metals as platinum, palladium, rhodium, and iridium are generally used as an active component. The catalysts which are formed of platinum/rhodium, platinum/palladium/rhodium, palladium/rhodium, and palladium alone are now in popular use. Many inventions directed to imparting improved heat resistance to the precious metal-containing purifying catalysts for the exhaust gas from an internal combustion engine have been proposed (JP-A-04-219140, JP-A-04-284847, JP-07-171392, etc.).
While the internal combustion engine of an automobile is driven, the driving condition of the engine of automobile frequently changes from idling to acceleration, from acceleration to constant-speed drive, from constant-speed drive to deceleration, or from constant-speed drive to acceleration. The atmosphere of the exhaust gas from the internal combustion engine is largely varied as a result. When the ability of the purifying catalyst at the reaction variable filed as implied above is studied in detail, the results hardly justify the conclusion that the conventional purifying catalysts for the exhaust gas from an internal combustion engine manifest a fully satisfactory purifying ability and that they respond fully satisfactorily to the purification of NO x in particular.
An object of this invention, therefore, is to provide a novel purifying catalyst for the exhaust gas from an internal combustion engine.
Another object of this invention is to provide a purifying catalyst for the exhaust gas from the internal combustion engine such as of an automobile which excels in the ability to respond quickly to the atmosphere of the exhaust gas varying greatly with the changes in the driving condition of the engine involving such phases as idling, acceleration, constant-speed drive, and deceleration, particularly a purifying catalyst for the exhaust gas from the internal combustion engine which excels in the ability to respond quickly to the purification of NO x .
We have pursued a diligent study on the purifying catalysts for the exhaust gas from an internal combustion engine to learn that a purifying catalyst for the internal combustion engine exhaust gas which is possessed of a plurality of catalyst layers comprising a specific combination of platinum metals, a cerium compound, and a refractory inorganic oxide excels in the ability to respond quickly to the changes in the atmosphere of the exhaust gas. The present invention has been perfected as a result.
SUMMARY OF THE INVENTION
The objects mentioned above are accomplished by the following aspects, (1) through (20), of this invention.
(1) A purifying catalyst for the exhaust gas from an internal combustion engine, containing rhodium, palladium, a cerium compound, and a refractory inorganic oxide as catalytic components, carried on a refractory carrier, and comprising at least two catalyst layers, i.e. a first catalyst layer containing the cerium compound and a second catalyst layer containing the palladium and containing the cerium compound in an amount of not more than 5% by weight as CeO 2 based on the amount of the second catalyst layer.
(2) A catalyst according to (1) above, wherein the first catalyst layer containing the cerium compound contains rhodium.
(3) A catalyst according to (1) above, wherein the rhodium content of the second catalyst layer containing the palladium is not more than 0.05% by weight based on the amount of the second catalyst layer.
(4) A catalyst according to (1) above, wherein the palladium content of the first catalyst layer containing the cerium compound is not more than 0.1% by weight based on the amount of the first catalyst layer.
(5) A catalyst according to (1) above, wherein the cerium compound and palladium are not substantially contained in one and the same catalyst layer.
(6) A catalyst according to (1) above, wherein the first catalyst layer containing the cerium compound forms an outer layer and the second catalyst layer containing the palladium an inner layer in the superposed catalyst layers.
(7) A catalyst according to (1) above, which contains platinum metals excluding rhodium and palladium.
(8) A catalyst according to (1) above, wherein the refractory inorganic oxide has a BET surface area in the range of 10 to 400 m 2 /g.
(9) A catalyst according to any of (1) through (8) above, wherein the rhodium content is in the range of 0.01 to 2 g, the palladium content in the range of 0.1 to 20 g, the cerium compound content calculated as CeO 2 in the range of 1 to 100 g, and the refractory inorganic oxide content in the range of 10 to 300 g per liter of the catalyst.
(10) A catalyst according to (7) above, wherein the total content of platinum metals excluding rhodium and palladium is in the range of 0.01 to 5 g per liter of the catalyst.
(11) A catalyst according to (1) above, wherein the second catalyst layer containing the palladium further contains a cerium compound having a BET surface area of not more than 20 m 2 /g or a crystal diameter of not less than 200 Å as determined by XRD.
(12) A catalyst according to (11) above, wherein the first catalyst layer containing the cerium compound further contains rhodium.
(13) A catalyst according to (11) above, wherein the rhodium content of the second catalyst layer containing the palladium is not more than 0.05% by weight based on the amount of the second catalyst layer.
(14) A catalyst according to (11) above, wherein the palladium content of the first catalyst layer containing the cerium compound is not more than 0.1% by weight based on the amount of the first catalyst layer.
(15) A catalyst according to (11) above, wherein the cerium compound and palladium are not substantially contained in one and the same catalyst layer.
(16) A catalyst according to (11) above, wherein the first catalyst layer containing the cerium forms an outer layer and the second catalyst layer containing the palladium an inner layer in the superposed catalyst layers.
(17) A catalyst according to (11) above, which contains platinum metals excluding rhodium and palladium.
(18) A catalyst according to (11) above, wherein the refractory inorganic oxide has a BET surface area in the range of 10 to 400 m 2 /g.
(19) A catalyst according to any of (11) through (18) above, wherein the rhodium content is in the range of 0.01 to 2 g, the palladium content in the range of 0.1 to 20 g, the cerium compound content calculated as CeO 2 in the range of 1 to 100 g, and the refractory inorganic oxide content in the range of 10 to 300 g per liter of the catalyst.
(20) A catalyst according to (17) above, wherein the total content of platinum metals excluding rhodium and palladium is in the range of 0.01 to 5 g per liter of the catalyst.
The catalyst of this invention, when used in the internal combustion engine of an automobile, for example, exhibits an excellent purifying ability in quick response to the atmosphere of the exhaust gas which varies largely with changes in the operating condition of the engine involving such phases as idling, acceleration, constant-speed drive, and deceleration, particularly an excellent purifying ability in quick response to NO x . It is exceptionally useful for the purification of the exhaust gas from an internal combustion engine.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Now, this invention will be described in detail below.
The purifying catalyst of this invention for the exhaust gas from an internal combustion engine contains rhodium, palladium, a cerium compound, and a refractory inorganic oxide as catalyst components and has formed on a refractory carrier at least two catalyst layers, i.e. a first catalyst layer containing the cerium compound and a second catalyst layer containing palladium.
The cerium compounds which are effectively used in this invention include oxides, carbonates, and sulfate products, for example. Among other cerium compounds cited above, the oxides prove particularly advantageous. The cerium oxides are not particularly limited so long as they have been obtained by calcining corresponding water-insoluble salts or water-soluble salts. The content of the cerium compound calculated as CeO 2 (hereinafter referred to "calculated as CeO 2 ") in the catalyst is appropriately in the range of 1 to 100 g, preferably 1 to 80 g, per liter of the catalyst. If the content of the cerium compound is less than 1 g, the catalyst will be deficient in the catalytic ability. If it exceeds 100 g, the excess will impair the economy of the catalyst without bringing about a proportionate addition to the effect thereof.
The palladium content in this invention appropriately is in the range of 0.1 to 20 g, preferably 0.1 to 15 g, per liter of the catalyst. If the palladium content is less than 0.1 g, the catalyst will be deficient in ability. If the content exceeds 20 g, the excess will impair the economy of the catalyst without bringing about a proportionate addition to the effect thereof. For this invention, the first catalyst layer containing the cerium compound mentioned above advantageously contain rhodium. The rhodium content in this invention is properly in the range of 0.01 to 2 g, preferably 0.02 to 1 g, per liter of the catalyst. If the rhodium content is less than 0.01 g, the catalyst will be deficient in ability. If the content exceeds 2 g, the excess will impair the economy of the catalyst without bringing about a proportionate addition to the effect thereof.
This invention prefers the second catalyst layer containing the palladium to avoid substantially containing rhodium. The expression "to avoid substantially containing rhodium" as used herein means that the rhodium content is not more than 0.05% by weight and preferably not more than 0.025% by weight based on the total weight of the relevant catalyst layer and especially that no rhodium is contained. If the rhodium content exceeds 0.05% by weight, the excess rhodium will react with palladium possibly to the extent of harming the ability of the catalyst.
This invention likewise prefers the first catalyst layer containing the cerium compound mentioned above to avoid substantially containing palladium. The expression "to avoid substantially containing palladium" as used herein means that the palladium content is not more than 0.1% by weight and preferably not more than 0.05% by weight based on the total weight of the relevant catalyst layer and especially that no palladium is contained. If the palladium content exceeds 0.1% by weight, the excess palladium will react with rhodium possibly to the extent of harming the ability of the catalyst.
This invention further prefers the second catalyst layer containing the palladium mentioned above to avoid substantially containing a cerium compound. The expression "to avoid substantially containing palladium" as used herein means that the cerium compound content is not more than 5% by weight and preferably not more than 3% by weight as CeO 2 based on the total weight of the relevant catalyst layer and especially that no cerium compound is contained. If the cerium compound content exceeds 5% by weight, the excess cerium compound will harm the catalyst by degrading the purifying ability in quick response to the NO x mentioned above.
Though the second catalyst layer containing palladium is preferred to avoid substantially containing a cerium compound as described above, it may contain such a specific cerium compound as will be described below.
Such cerium compound which is usable has a Brunauer-Emmett-Teller (BET) specific surface area of not more than 20 m 2 /g or a crystal diameter of not less than 200 Å as determined by an X-ray diffractometer (XRD with Cu--Ka as light source). If the specific surface area of the cerium compound exceeds 20 m 2 /g or the crystal diameter of the cerium compound as determined by the XRD is less than 200 Å, the cerium compound will be at a disadvantage in degrading the catalyst in the purifying ability in quick response. The cerium compound of a quality such that the specific surface area thereof may be not more than 20 m 2 /g or the crystal diameter thereof as determined by the XRD may be not less than 200 Å can be obtained by a method which comprises causing a cerium compound of a quality such that the specific surface area thereof may be not less than 20 m 2 /g or the crystal diameter thereof as determined by the XRD may be not more than 200 Å to undergo forcibly accelerated crystallization in an atmosphere of an elevated temperature or by a method which comprises hydrolyzing or precipitating a water-soluble salt of cerium prior to the preparation of a cerium compound and, while the product thereof is still in the form of a hydroxide or a hydrate, forcibly forming a cerium compound of the quality fulfilling the conditions mentioned above, for example.
The content of this specific cerium compound in the second catalyst layer is in the range of 3 to 80% by weight as CeO 2 based on the amount of the second catalyst layer, providing that this content should be calculated separately of the content of the cerium compound par liter of the catalyst mentioned above.
Further, this invention prefers the first catalyst layer containing the cerium compound mentioned above to avoid substantially containing palladium and the second catalyst layer containing the palladium mentioned above to avoid substantially containing the cerium compound. Specifically, it is particularly appropriate that neither of the two catalyst layers contains the cerium compound and palladium simultaneously.
The purifying catalyst of this invention for the exhaust gas from an internal combustion engine prefers the first catalyst layer containing the cerium compound mentioned above to form an outer layer and the second catalyst layer containing the palladium mentioned above to form an inner layer, respectively as deposited on a refractory carrier, particularly a refractory three dimensional carrier structure.
The purifying catalyst of this invention for the exhaust gas from an internal combustion engine may contain platinum metals excluding rhodium and palladium. The platinum metals excluding rhodium and palladium are platinum, iridium, etc. for example. The amount of the platinum metal to be used herein is properly in the range of 0.01 to 5 g, preferably 0.01 to 2 g, per liter of the catalyst. If the amount of the platinum metal to be used is less than 0.01 g, the catalyst will be deficient in ability. If this amount exceeds 5 g, the excess platinum metal will impair the economy of the catalyst without producing a proportionate addition to the effect thereof.
As concrete examples of the refractory inorganic oxide o be effectively used herein, activated aluminas such as γ-alumina, δ-alumina, η-alumina, and θ-alumina; α-alumina; silica; titania; and zirconia or complex oxides thereof such as silica-alumina, alumina-titania, alumina-zirconia, silica-titania, silica-zirconia, and titania-zirconia, and mixtures thereof maybe cited. These refractory inorganic oxides generally come in a powdery form. Appropriately, the Brunauer-Emmett-Teller (hereinafter referred to as "BET") specific surface area of the inorganic oxide is in the range of 10 to 400 m 2 /g, preferably 20 to 300 m 2 /g. The amount of the refractory inorganic oxide to be used herein is appropriately in the range of 10 to 300 g, preferably 50 to 250 g, per liter of the refractory three dimensional structure. If the amount to be used is less than 10 g/liter, the catalyst will fail to acquire a fully satisfactory catalytic ability. If this amount exceeds 300 g/liter, the excess will harm the catalyst by inducing an undue rise in back pressure.
The refractory three dimensional structure to be used herein may be a pelletized carrier or a monolithic carrier. This invention prefers the monolithic carrier to the pelletized carrier. As typical examples of the monolithic carrier, ceramic foam, open-flow type ceramic honeycomb, wall-flow type honeycomb monolith, open-flow type metal honeycomb, metallic foam, and metal mesh may be cited. Among other monolithic carriers mentioned above, the open-flow type ceramic honeycomb or the metallic honeycomb is used particularly advantageously. As concrete examples of the material used advantageously for the ceramic honeycomb carrier, cordierite, mullite, α-alumina, zirconia, titania, titanium phosphate, aluminum titanate, betalite, spondumen, aluminosilicate, and magnesium silicate may be cited. Among other materials mentioned above, those based on cordierite prove particularly advantageous. In the metal honeycomb carriers, those which are formed in a one body using such oxidation-resistant refractory metals as stainless steel and Fe--Cr--Al alloy are used particularly advantageously.
These monolithic carriers are manufactured by the extrusion molding technique or the technique of tightly rolling a sheet-like element. The mouths of these monolithic carriers for passing gas (cell shapes) may be in the form of hexagons, tetragons, triangles, or corrugations. The cell density (number of cells/unit cross section) in the range of 100 to 600 cells/square inch, preferably 200 to 500 cells/square inch, is sufficient for effective use.
The purifying catalyst of this invention for the exhaust gas from an internal combustion engine, when necessary, may incorporate therein an alkaline earth metal compound and a rare earth metal oxide for the purpose of enhancing the thermal stability of the refractory inorganic oxide. It may further incorporate therein iron, cobalt, or nickel exhibiting the oxygen storage ability, chromium, manganese, niobium, tungsten, zinc, gallium, germanium, indium, tin, bismuth, or alkali metal compounds.
Now, this invention will be described more specifically below with reference to working examples. It should be noted, however, that this invention is not limited to these examples.
EXAMPLE 1
An aqueous slurry was prepared by subjecting 1200 g of activated alumina (γ-Al 2 O 3 with a BET specific surface area of 155 m 2 /g, the remarks will apply invariably to the following examples and controls), aqueous solution of palladium nitrate containing 15 g of palladium, and deionized water added thereto to wet pulverization by the use of a ball mill. One liter of monolithic carriers made of cordierite (148 mm in major diameter, 84 mm in minor diameter, and 96 mm in length) and having 400 cells per square inch of cross section were immersed in the slurry. The wet monolithic carriers removed from the slurry were blown with compressed air to expel excess slurry, dried, and calcined at a temperature in the range of 500° C. for a period in the range of 1 hour to complete an inner catalyst layer.
Then, an aqueous slurry was prepared by subjecting 800 g of activated alumina, 200 g of commercially available cerium oxide (CeO 2 with a BET surface area of 149 m 2 /g, the remarks will apply invariably to the following examples and controls), aqueous solution of rhodium nitrate containing 3 g of rhodium, and deionized water added thereto to wet pulverization by the use of a ball mill. One liter of the monolithic carriers of cordierite coated with the inner catalyst layer mentioned above were immersed in the aqueous slurry. The wet monolithic carriers removed from the slurry were blown with compressed air to expel excess slurry, dried, and calcined at a temperature of 500° C. for a period of 1 hour to form an outer catalyst layer and obtain a complete catalyst. The catalyst was found to contain in the inner layer 1.5 g of palladium and 120 g of activated alumina per liter of the carrier and in the outer layer 0.3 g of rhodium and 80 g of activated alumina per liter of the carrier as shown in Table 1.
EXAMPLE 2
An aqueous slurry for the formation of an inner catalyst layer was prepared by subjecting 1140 g of activated alumina, 60 g of cerium oxide, aqueous solution of palladium nitrate containing 15 g of palladium, and deionized water added thereto to wet pulverization by the use of a ball mill. Thereafter, a complete catalyst was obtained by preparing an inner catalyst layer and an outer catalyst layer by following the procedure of Example 1.
Control 1
An aqueous slurry for the formation of an inner catalyst layer was prepared by subjecting 800 g of activated alumina, 400 g of cerium oxide, aqueous solution of palladium nitrate containing 15 g of palladium, and deionized water added thereto to wet pulverization by the use of a ball mill. Thereafter, a complete catalyst was obtained by preparing an inner catalyst layer and an outer catalyst layer by following the procedure of Example 1.
Control 2
An aqueous slurry for the formation of an inner catalyst layer was prepared by subjecting 1100 g of activated alumina, 100 g of cerium oxide, aqueous solution of palladium nitrate containing 15 g of palladium, and deionized water added thereto to wet pulverization by the use of a ball mill. Thereafter, a complete catalyst was obtained by preparing an inner catalyst layer and an outer catalyst layer by following the procedure of Example 1.
Control 3
An aqueous slurry for the formation of an inner catalyst layer was prepared by subjecting 800 g of activated alumina, 400 g of cerium oxide, aqueous solution of dinitrodianmine-platinum containing 15 g of platinum, and deionized water added thereto to wet pulverization by the use of a ball mill. Thereafter, a complete catalyst was obtained by preparing an inner catalyst layer and an outer catalyst layer by following the procedure of Example 1.
The compositions of the catalysts prepared in the working examples and controls cited above are collectively shown in Table 1.
TABLE 1______________________________________Composition of inner Composition of outercatalyst layer (g/l) catalyst layer (g/l) Al.sub.2 O.sub.3 CeO.sub.2 Al.sub.2 O.sub.3 CeO.sub.2______________________________________Example 1 Pd = 1.5 120 0 Rh = 0.3 80 20Example 2 Pd = 1.5 114 6 Rh = 0.3 80 20Control 1 Pd = 1.5 80 40 Rh = 0.3 80 20Control 2 Pd = 1.5 110 10 Rh = 0.3 80 20Control 3 Pt = 1.5 80 40 Rh = 0.3 80 20______________________________________
Evaluation of Catalyst
The catalysts obtained in Examples 1 and 2 and Controls 1 through 3 were subjected to durability test in order to obtain catalyst performance. A sample catalyst was set in place in the exhaust system of a commercially available electronically controlled gasoline engine (8 cylinders, 4400 cc) and tested for durability to withstand the impact of the exhaust gas. The engine was driven in the mode of 60 seconds of constant-speed drive and 6 seconds of deceleration (during the course of the deceleration, the fuel supply was cut and the catalyst was exposed to the harsh condition of an oxidizing atmosphere at an elevated temperature) and the catalyst was left standing for 50 hours under the condition such that the exhaust gas temperature at the inlet to the catalyst might be 850° C. during the constant-speed drive. Then, the catalyst was set in place in a commercially available electronically controlled gasoline engine (4 cylinders, 2000 cc) and tested for catalyst performance using the 10.15 mode, the standard drive mode in Japan which repeats acceleration, deceleration, constant-speed drive, and idling. The results are shown collectively in Table 2.
TABLE 2______________________________________ Purification Purification Purification ratio of CO (%) ratio of HC (%) ratio of NO (%)______________________________________Example 1 84 83 82Example 2 84 82 79Control 1 80 78 71Control 2 81 79 74Control 3 80 75 75______________________________________
It is clearly noted from the data of Table 2 that, in the practical drive involving acceleration and deceleration and constant-speed drive, the catalysts of the working examples showed highly satisfactory ability to deprive the exhaust gas of NO x and of CO and HC as well, whereas the catalysts of the controls showed a problematic ability to deprive the exhaust gas particularly of NO x .
EXAMPLE 3
A cerium oxide showing a specific surface area of 10 m 2 /g and a crystal diameter of about 400 A was obtained by calcining commercially available cerium carbonate in an electric oven at 800° C. for 10 hours. An aqueous slurry was prepared by subjecting 400 g of the cerium oxide, 800 g of activated alumina (γ-Al 2 O 3 with a BET specific surface area of 155 m 2 /g, the remarks will apply invariably to the following examples and controls), aqueous solution of palladium nitrate containing 15 g of palladium, and deionized water added thereto to wet pulverization by the use of a ball mill. One liter of monolithic carriers made of cordierite (148 mm in major diameter, 84 mm in minor diameter, and 96 mm in length) and having 400 cells per square inch of cross section were immersed in the slurry. The wet monolithic carriers removed from the slurry were blown with compressed air to expel excess slurry, dried, and calcined at a temperature of 500° C. for a period of 1 hour to complete an inner catalyst layer.
Then, an aqueous slurry was prepared by subjecting 800 g of activated alumina, 200 g of commercially available cerium oxide (CeO 2 with a BET surface area of 149 m 2 /g), rhodium nitrate containing 3 g of rhodium, and deionized water added thereto to wet pulverization by the use of a ball mill. One liter of the monolithic carriers of cordierite coated with the inner catalyst layer mentioned above were immersed in the aqueous slurry. The wet monolithic carriers removed from the slurry were blown with compressed air to expel excess slurry, dried, and calcined at a temperature of 500° C. for a period of 1 hour to form an outer catalyst layer and obtain a complete catalyst.
The purifying catalyst for the exhaust gas from an internal combustion engine was found to contain 1.5 g of palladium and 0.3 g of rhodium per liter of the refractory three dimensional structure.
EXAMPLE 4
A cerium oxide showing a specific surface area of 18 m 2 /g and a crystal diameter of about 210 Å was obtained by calcining the same cerium carbonate as used in Example 3 at 700° C. for 5 hours. Then, a complete catalyst was obtained by following the procedure of Example 1 while using the cerium oxide mentioned above as the cerium compound for the inner layer.
Control 4
A complete catalyst was obtained by following the procedure of Example 3 while using as the cerium compound for the inner layer the same commercially available cerium oxide used for the outer layer.
The compositions of the catalysts obtained in Examples 3 and 4 and Control 4 are shown in Table 3.
TABLE 3__________________________________________________________________________Inner catalyst layer Outer catalyst layerPlatinum Specific Crystal Platinum Specific Crystalmetal Al.sub.2 O.sub.3 CeO.sub.2 surface area diameter metal Al.sub.2 O.sub.3 CeO.sub.2 surface area diameter(g/l) (g/l) (g/l) (m.sup.2 /g) (Å) (g/l) (g/l) (g/l) (m.sup.2 /g) (Å)__________________________________________________________________________Example 3Pd = 1.5 80 40 10 400 Rh = 0.3 80 20 149 100Example 4Pd = 1.5 80 40 18 210 Rh = 0.3 80 20 149 100Control 4Pd = 1.5 80 40 149 100 Rh = 0.3 80 20 149 100__________________________________________________________________________
Evaluation of Catalyst
The catalysts obtained in Examples 3 and 4 and Control 4 were subjected to practical service with an engine and then tested for catalyst performance. A sample catalyst was set in place in the exhaust system of a commercially available electronically controlled gasoline engine (8 cylinders, 4400 cc). and tested for durability to withstand the impact of the exhaust gas. The engine was driven in the mode of 60 seconds of constant-speed drive and 6 seconds of deceleration (during the course of the deceleration, the fuel supply was cut and the catalyst was exposed to the harsh condition of an oxidizing atmosphere at an elevated temperature) and the catalyst was left standing for 50 hours under the condition such that the exhaust gas temperature at the inlet to the catalyst might be 850° C. during the constant-speed drive. Then, the catalyst was set in place in a commercially available electronically controlled gasoline engine (4 cylinders, 2000 cc) and tested for catalyst performance using the 10.15 mode, the standard drive mode in Japan which repeats acceleration, deceleration, constant-speed drive, and idling. The results are shown collectively in Table 4.
TABLE 4______________________________________ Purification Purification Purification ratio of CO (%) ratio of HC (%) ratio of NO (%)______________________________________Example 3 84 83 82Example 4 84 82 80Control 4 80 78 71______________________________________
It is clearly noted from the data of Table 4 that, in the practical drive involving acceleration and deceleration and constant-speed drive, the catalysts of the working examples showed highly satisfactory ability to deprive the exhaust gas of NO x and of CO and HC as well, whereas the catalyst of the control showed a problematic ability to deprive the exhaust gas particularly of NO x . | A purifying catalyst for the exhaust gas from the internal combustion engine of an automobile, for example, is disclosed which excels in the purifying ability in quick response to the atmosphere of the exhaust gas largely varying with changes in the operating condition of the engine involving such phases as idling, acceleration, constant-speed drive, and deceleration. The purifying catalyst contains rhodium, palladium, a cerium compound, and a refractory inorganic oxide as catalytic components carried on a refractory carrier and comprises at least two catalyst layers, namely a catalyst layer containing the cerium compound and a catalyst layer containing palladium. | 8 |
BACKGROUND OF THE INVENTION
Field of Invention
The present invention relates to a clothing steam ironing apparatus, particularly to one suitable for ironing clothing while the clothing is hanging.
Description of the Related Art
Steam ironing for clothing has advantages of high efficiency, good ironing effect, and no bad influence to the surface and texture of the clothing. Further, due to elimination of the need of a flat bench, hanging arrangement for steam ironing is especially convenient.
However, some disadvantages exist in prior ironing apparatus in hanging arrangement. For example, because there is no support at the back side of the hanging clothing, the ironing operation is a bit difficult and the clothing will not be ironed as smooth as it would be by ironing with pressure (such as, the back side of the clothing is supported by a rigid body). Thus the ironing efficiency and effect may not satisfy the increasing demand nowadays.
In addition, prior clothing steam ironing apparatus could be only used in clothing ironing, and could not perform other useful function like dust elimination. Accordingly, prior ironing apparatus only has a single function.
SUMMARY OF THE INVENTION
The present invention has been made to overcome or alleviate at least one aspect of the above mentioned disadvantages.
According to an aspect of the present invention, there is provided a clothing steam ironing apparatus, comprising an ironing component with an ironing panel. Steam ejection holes for ejecting steam to iron clothing and air suction holes for generating a suck force to the clothing are provided in the ironing panel.
Preferably, the ironing component further comprises a steam chamber and an air chamber separated from the steam chamber, the steam chamber being in fluid communication with the steam ejection hole and the air chamber being in fluid communication with the air suction hole.
Preferably, the ironing component is provided with an air vent being in fluid communication with the air chamber, a fan is provided in the air chamber.
Preferably, a dust collection device equipped with a filter is provided between the fan and the air suction hole.
Preferably, the steam ejection holes are located at the center of the ironing panel and the air suction holes are located at the periphery of the ironing panel.
Preferably, the clothing steam ironing apparatus further comprises a mount for providing steam.
Preferably, a vertical telescopic pole bracket is provided in the mount.
Preferably, the clothing steam ironing apparatus further comprises a fan control switch for switching the fan on and off and for adjusting the velocity of the wind blown by the fan.
According to another aspect, present invention provides a clothing steam ironing apparatus, comprising a mount including a steam generating device therein and an ironing head which connects at an end of a steam pipe led from the mount and connects with the steam generating device through the steam pipe; wherein the ironing head comprises a steam chamber and an air suction chamber separated from the steam chamber; steam ejection holes connecting with the steam chamber and air suction holes connecting with the air suction chamber are dispersedly formed in an ironing panel of the ironing head; a fan is mounted in the mount; an air discharge port of the fan is in fluid communication with an air vent formed in a housing of the mount; an air intake port of the fan connects with one end of an air intake pipe, the other end of the air intake pipe connects with the air suction chamber of the ironing head.
Preferably, the clothing steam ironing apparatus further comprises a dust collection device which is provided in the mount and located between the air intake port of the fan and the air intake pipe, or the dust collection device is provided in the air suction chamber.
According to another aspect, the present invention provides a clothing steam ironing apparatus with cleaning function, the apparatus comprises a mount including a steam generating device therein, the mount is equipped with a vertical telescopic pole bracket, a steam pipe connects with the steam generating device at one end and connects with an ironing head at the other end, wherein the ironing head comprises a steam ejection chamber and an air suction chamber; steam ejection hole connecting with the steam chamber and air suction hole connecting with the air suction chamber are formed in an ironing panel of the ironing head; a fan is mounted in the air suction chamber; a dust collection device with a filter is provided between the fan and the air suction hole, and an air vent for the air suction chamber is provided in a housing of the ironing head at the rear lower side of the fan.
According to yet another aspect, present invention provides a clothing steam ironing apparatus, comprising a mount including a steam generating device therein and an ironing head which connects at an end of a steam pipe led from the mount and connects with the steam generating device through the steam pipe; wherein the ironing head comprises a steam chamber and an air suction chamber separated from the steam chamber; steam ejection holes connecting with the steam chamber and air suction holes connecting with the air suction chamber are dispersedly formed in an ironing panel of the ironing head; the steam chamber is in fluid communication with the steam pipe and the steam ejection holes, the air chamber is in fluid communication with the air suction holes; a fan is mounted in the ironing head; an air intake port and an air discharge port of the fan are in fluid communication with the air chamber and an air outlet formed in the ironing head, respectively.
Compared with existing technology, present invention is advantageous in at least following aspects:
Due to the presence of the air suction holes, the ironing side of the clothing will stick to the ironing panel when the ironing panel contacts the clothing to be ironed. The operator could move the ironing apparatus when ironing the clothing, so it is convenient for the user to iron the clothing; meanwhile, the clothing could be ironed smooth. Therefore, both of the ironing efficiency and effect are enhanced.
By combining air suction holes and dust collection device, the clothing, as well as bedding, sofa and seat cushion could be dusted when the ironing panel of the ironing head contacts them. Furthermore, by virtue of the high temperature of the steam, the ironing apparatus of present invention further provide a sterilization function, so that the hazard to health of human, especially old people and children, incurred by the dust, pollen, acarus and other pollutants might be reduced. Thus, the clothing will undergo a cleaning and sterilizing process when being ironed by the ironing apparatus of present invention.
In a preferred embodiment, a fan control switch is provided, which enables steam ironing and dusting operations simultaneously, or independently.
BRIEF DESCRIPTION OF THE DRAWING
FIG. 1 is a schematic view of the configuration of the clothing steam ironing apparatus according to a first embodiment of present invention;
FIG. 2 is a schematic view of an ironing component of the clothing steam ironing apparatus according to a first embodiment of present invention;
FIG. 3 is a schematic view of the configuration of the clothing steam ironing apparatus according to a second embodiment of present invention;
FIG. 4 is a schematic view of an ironing component of the clothing steam ironing apparatus according to a second embodiment of present invention;
FIG. 5 is a schematic view of the configuration of the clothing steam ironing apparatus according to a third embodiment of present invention;
FIG. 6 is a schematic view of an ironing component of the clothing steam ironing apparatus according to a third embodiment of present invention.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
Preferred embodiments of the present invention will be described hereinafter in detail with reference to the attached drawings, wherein the like reference numerals refer to the like elements throughout the specification. These embodiments should not be construed as being limited to the embodiment set forth herein, rather for illustrative purpose.
In description hereafter, “clothing steaming ironing apparatus” may be referred to as “clothing steam hanging ironing apparatus”. Thus, though presented in different expressions, the two terms have substantially same meaning.
As illustrated in FIGS. 1, 2 , the first embodiment of the clothing steam ironing apparatus according to present invention comprises an ironing component 3 which includes an ironing panel (better seen in FIG. 2 ). Steam ejection holes 7 and suction holes 8 are provided in the ironing panel, and during use, the steam is ejected from the steam ejection holes 7 to iron the clothing while the suction holes 8 inhale air to generate a sucking force to the clothing.
In clothing steam ironing apparatus according to present invention, due to the sucking force provided by the suction holes 8 , the side of the clothing being ironed is stuck to the ironing panel closely. The operator could move ironing component while ironing the clothing, which is convenient for the user on the one hand, and on the other hand, the fabric of the clothing could be ironed smooth. Therefore, both of the ironing efficiency and effect are enhanced.
In prefer embodiment of present invention, as illustrated in FIG. 2 , the ironing component 3 further comprises a steam chamber 5 and an air suction chamber 6 separated from the steam chamber 5 . The steam chamber 5 is in fluid communication with the steam ejection holes 7 , and the air suction chamber 6 is in fluid communication with the suction holes 8 .
It should be noted that, the configuration of the steam chamber and the air suction chamber taught above is a preferred embodiment of present invention, but present invention is not limited to that and those skilled in the art could adopt any possible ways. In other words, any suitable configuration that could provide an appropriate channel for conveying steam and air to the ironing panel could be employed as alternatives to the configuration illustrated in FIGS. 1-2 .
Actually, referring to FIG. 4 , another configuration of steam chamber and air suction chamber is illustrated. In the embodiment of FIG. 4 , a dust collection and filter 13 is provided between the suction holes 8 and the fan 9 inside the air suction chamber 6 .
Referring to FIG. 2 again, according to the first embodiment of present invention, ironing component 3 is provided with an air outlet 10 which is in fluid communication with the air suction chamber 6 . Alternatively, the air outlet 10 could be provided in the mount 1 . Accordingly, the location of the air outlet shown in FIG. 2 shall not be construed as a limit to present invention. Actually, according to another embodiment of present invention, the air outlet 10 could be formed in the mount 1 as illustrated in FIG. 5 as well.
FIG. 2 illustrates that the fan 9 is provided in the air suction chamber 6 . The air intake port and the air discharging port of the fan 9 are in fluid connection with the air suction chamber 6 and the outlet 10 , respectively. The intake of air is achieved by the rotation of the fan 9 . To control the fan, a fan control switch (not shown) is provided for starting up and turning off the fan and for adjusting the wind speed outputted by the fan. Thus, an operator could select a suitable wind speed which corresponds to the force of the sucking force as desired, and switch the fan on and off independently. That is, the switch enables a flexible control over the fan, the operator could select use or not to use the fan during ironing process, or the operator could use the fan to dust the clothing only, i.e., without ironing the clothing.
According to the first embodiment of present invention, as illustrated in FIG. 2 , the steam ejection holes 7 are dispersedly formed in center of the ironing panel, and the suction holes 8 are formed at the periphery of the ironing panel. Correspondingly, in the first embodiment, the steam chamber 5 and the air suction chamber 6 are separated from each other, and more specifically, the centrally positioned steam chamber 5 are surrounded by the air suction chamber 6 .
According to the first embodiment, the mount 1 is used to provide steam, that is, a steam generator such as configured as a water tank with an electric heater therein is provided in the mount 1 . A steam pipe 2 connects with the steam outlet of the steam generator and is led from the mount 1 , preferably, the steam pipe 2 is a flexible heat-resistant and heat insulation pipe. The other end of the steam pipe 2 communicates with the steam chamber 5 . It should be understood that present invention is not limited to the steam generator and steam pipe configuration as above, those skilled in the art could configure the steam generator otherwise and arrange the steam pipe elsewhere according to the requirement of actual application.
According to the first embodiment of present invention, a vertical telescopic pole bracket 4 is provided in the mount 1 as a bracket for placing the ironing component and for hanging the clothing. The bracket 4 , being of a telescopic pole, is advantageous in storing the ironing apparatus when not in use, and in allowing the height of the bracket to be adjusted, which is convenient for ironing work. Per the actual application, those skilled in the art could employ a fixed type mount or a movable one.
FIGS. 3, 4 illustrate a second embodiment of present invention. In FIGS. 3, 4 same elements are denoted by same reference sign, for the purpose of clarity, the description about same elements will not be repeated.
FIG. 4 illustrates the control switch 12 of the fan. According to the second embodiment of present invention, the configuration of the steam chamber 5 and the air suction chamber 6 is different from that in the first embodiment. More specifically, though the steam chamber 5 and the air suction chamber 6 are separated from each other too, as illustrated in FIG. 4 , the area that the steam chamber 5 contacts the ironing panel is much larger than the area that the air suction chamber 6 contacts the ironing panel. Correspondingly, the locations of the steam ejection holes 7 and suction holes 8 are also different from that in the first embodiment. In the second embodiment, the steam ejection holes 7 and the suction holes 8 are formed at the upper side and the lower side of the ironing panel respectively.
In addition, in order to improve the dust cleaning effect, a dust collection device 13 with a filter is provided between the fan 9 and the suction holes 8 . Preferably, the dust collection device 13 is a vertical flat box-like body, with a front end and a rear end opened. The filter for preventing the dust entering into the dust collection device 13 from leaving is mounted in the inside of the rear end opening of the flat box-like body. The dust collection device 13 is inserted and fitted in the air suction chamber 6 though an opening at the underside of a housing of the ironing component 3 . The dust collection device 13 could be integrally detached from the ironing component 3 , so that the user could dump the dust accumulated in the dust collection device and clean the filter. An air vent 11 is provided in the housing of the ironing component 3 at the rear lower side (or rear upper side) of the fan 9 , the air drawn into the air suction chamber 6 by the fan 9 though the air suction holes 8 flow out through the air vent 11 . The air flow as discussed above will generate a sucking force acted on the clothing to be ironed or cleaned, meanwhile serve as a cooling air flow for the fan.
In FIGS. 5, 6 , the third embodiment of present invention is illustrated, and the elements same with that of the first and second embodiment are denoted by the same reference signs. For the same configurations, the descriptions will be omitted.
Referring to FIG. 5 , in accordance with the third embodiment of present invention, the location of the fan 9 is different from that in the first and second embodiments. More specifically, the fan 9 is provided in the mount 1 . The air discharging port of the fan 9 is in fluid communication with the air outlet 10 formed in a housing of the mount 1 , and the air intake port of the fan 9 connects with a flexible intake pipe 14 . The other end of the intake pipe 14 is in fluid communication with the air suction chamber 6 of the ironing component 3 .
Besides, according to the third embodiment of present invention, a suction adjusting valve 15 is provided in the ironing component 3 . The valve 15 could be configured as a ring body and mounted at the lower end of the ironing component 3 . An air inhaling hole is formed in the ring body of the valve 15 , and a corresponding air inhaling hole communicating with the air suction chamber 6 could be provided in the ironing component 3 . By rotating the ring body, the air flow through the two air inhaling holes could be adjusted, up to the maximum flow rate or be reduced to zero (closed up). Thus the sucking force acted on the clothing to be ironed could be adjusted to meet various ironing requirements for different materials of the clothing.
Preferably, a filter 16 is provided in the housing of the mount 1 and fits with the air outlet 10 , so that the air discharged by the fan 9 is filtered by the filter 16 . To facilitate the cleaning work, the filter 16 preferably is removably mounted in the housing of the mount.
According to present invention, the fan could be provided in the ironing component or be provided in the mount, correspondingly, the dust collection device could be arranged in the ironing component or be arranged in the mount. As a basic teaching of the principle of present invention, those skilled in the art could readily envisage other modifications suitable for actual need.
Although several exemplary embodiments have been shown and described, it would be appreciated by those skilled in the art that various changes or modifications may be made in these embodiments without departing from the principles and spirit of the disclosure, the scope of which is defined in the appended claims and their equivalents. | Disclosed is a clothing steam ironing apparatus, comprising an ironing component ( 3 ) with an ironing panel, steam ejection holes ( 7 ) for ejecting steam to iron a clothing and air suction holes ( 8 ) for generating a suck force to the clothing are provided in the ironing panel. | 3 |
CROSS-REFERENCE TO PRIOR APPLICATION
This application is a continuation-in-part of co-pending Application Ser. No. 144,809, filed on May 19, 1971 which issued as a patent on October 30, 1973, now U.S. Pat. No. 3,769,098.
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to an improvement in the method of manufacturing fine powders of metal halide.
2. Description of the Prior Art
Chromium chloride, chromium bromide, aluminum chloride, aluminum bromide, etc. are used for surface treatment, such as in chromium cementation; aluminum cementation; chromium evaporation and aluminium evaporation of steel products. These metal halides are also used as the materials for the manufacture of pure metallic powders of these metals.
For the manufacture of these metal halides, a wet system has generally been adopted so far. However, in the case of the wet system, since a hydrate is liable to be produced, it is difficult to obtain an anydrous metal halide. Also, since a metal halide containing moisture produces oxide upon the surface treatment of steel products, such a metal halide containing moisture cannot be employed for surface treatment of steel.
On the other hand, in the case of a dry system, for instance, chromium chloride can be manufactured by the reaction of hydrogen chloride gas with chromium as described below:
Cr + 2 HCl → CrCl.sub.2 + H.sub.2.
However, chromium chloride, when produced, assumes the shape of a needle or mass, and in order to make such chromium chloride into fine powders, these materials must be mechanically pulverized because chromium chloride has the properties of deliquescence. However, such pulverization is industrially difficult in operation and the obtaining of yields of chromium chloride powder in abundance is impossible.
SUMMARY OF THE INVENTION
This invention aims at providing a method of manufacturing the fine powders of anhydrous metal halide industrially and easily. The invention also relates to a method of manufacturing fine powders of metal halide, which comprises evaporating a metal halide by heating to its fusing point or higher, an occluded body of the metal halide in a receptacle in a heating chamber, and then drying an inert gas at a low temperature; the inert gas is supplied in the heating chamber and the metal halide is evaporated and quenched, whereby, the halide is made into fine powders and the fine powders of that metal halide are emitted from the heating chamber in a dry state.
Further, this invention also relates to a method of manufacturing a fine powder-like lubricant consisting of chromium sulfide. The invention further relates to a process of manufacturing a fine powder-like lubricant, which comprises evaporating chromium halide by heating to its fusing point or higher, an occluded body of chromium halide in a receptacle in the heating chamber, and then supplying a dried mixed gas consisting of inert gas and hydrogen sulfide gas at a low temperature to the heating chamber; by the reaction of evaporated chromium halide with hydrogen sulfide gas, chromium sulfide is produced and chromium sulfide is quenched, whereby, the chromium sulfide is made into fine powders, and then the fine powders of chromium sulfide are emitted to the heating chamber in a dry state.
Furthermore, this invention relates to a process of wear-proof and corrosion-proof treatment by which both improved wear-proof and corrosion-proof metal products, such as steel products, or non-ferrous metals can be obtained.
The process of improving wear-proof metal products, such as, for instance, gears made of carbon steel, so far has been a known chemical process. For example, carburizing, hardening or nitriding and sulphurizing is known, and a physical process, such as induction hardening, is also known. On the other hand, other means for obtaining wear-proof liquid-like lubricant or powder-like lubricant are also known.
However, in the case of the improvement in wear-proofing mentioned above, there was a defect that the simultaneous improvement of wear-proofing and corrosion-proofing is impossible.
This invention aims at providing a process of wear-proofing and corrosion-proofing treatment by which both wear-proof and corrosion-proof metals can be improved. The invention relates to a process of wear-proof and corrosion-proof treatment of metal products, which comprises forming a chromium zone beforehand on the surface of metal products, such as iron and steel, or non-ferrous metals; and reacting the chromium with nitrogen, whereby chromium nitride is produced on the surface of the metal products.
For an understanding of the principles of the invention, reference is made to the following description of typical embodiments thereof as illustrated in the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
In the Drawings:
FIG. 1 is a perspective view showing a hollow cylindrical metal halide occluded body;
FIG. 2 is a longitudinal sectional side view showing manufacture of metal halide according to this invention;
FIG. 3 is a view showing a longitudinal temperature distribution of a retort;
FIG. 4 is a view showing a temperature distribution of a section of the retort;
FIG. 5 is a longitudinal sectional side view showing the reaction of sulphur with metal products cemented with chromium or plated with chromium, performed in salt;
FIG. 6 is an enlarged schematic view showing a section through the surface of the metal products obtained according to the invention after a wear-proof and a corrosion-proof treatment was performed;
FIG. 7 is a diagram graphically showing a result of a wear-proof and corrosion-proof test; and
FIG. 8 is a longitudinal sectional side view showing appratus in which treatment by the reaction of chromium with sulphur is performed in the mixed gas atmosphere.
DESCRIPTION OF PREFERRED EMBODIMENTS
First, as shown in FIG. 1, a metal halide occluded body 1, formed in the shape of a hollow cylinder, is manufactured from a porous body out of the same kind of metal (chromium in case of chromium halide); in this process, metal halide (for instance, chromium halide) is occluded in such a way that it does not contain carbon and oxidizing agent, such as moisture and hydroxyl; the resulting metal halide occluded body is placed in a retort 2 (shown in FIG. 2).
Next, as seen in FIG. 2, inert gas, such as argon or nitrogen gas is supplied from a feed pipe 4 with a valve 3 connected to one end of the retort 2 and the air in the retort is replaced by the inert gas. Then, heating was carried out from the outer periphery of the retort 2 by means of an electric furnace 5 and thus a stream of said metal halide is generated in the retort. Then, a dried inert gas at low temperature is blown into the retort from the feed pipe 4 at one end of the retort 2. Evaporated metal halide in said retort is quenched with the inert gas (in order to perform a further quenching, the retort 2 is sometimes cooled by means of a cooling means 5') whereby the evaporated metal halide is made into fine powders and the stream of fine powders of this metal halide in inert gas is withdrawn into a storage tank 8 which is maintained in a dried condition from the other end of the retort 2 through a feed pipe 7 with a valve 6 by means of which said inert gas stream is admitted.
At the upper part of the storage tank 8, there is a filter 9 for venting the inert gas and preventing the escape of fine powders of the metal halide; at the lower part of the storage tank 8, there is an exhaust port 10' having a valve 10.
FIG. 3 shows a longitudinal temperature distribution curve for the retort 2, in which: θ 1 indicates a temperature lower than the fusing point of metal halide, θ 2 indicates a temperature at the heating zone of the retort, and this temperature is higher than the fusing point of metal halide, θ 3 indicates a temperature lower than θ 2 , and this temperature is lower than the fusing point of metal halide; in particular, there is no need of heating or heat retaining, but rather a remarkably lower temperature (about 600°-900°C) than θ 2 is suitable for making evaporated metal halide into fine powders.
As to the temperature distribution in the retort, shown in section in FIG. 3, it is necessary to maintain the temperature where inert gas flows lower than the temperature at the point where the metal halide occluded body is heated and it is also necessary to make the former temperature lower than the fusing point of metal halide in order to solidify the evaporated metal halide.
Further, in carrying out this invention, the heating chamber, (for instance, the retort) may be longitudinally or obliquely directed, instead of laterally, as shown in the drawing; or its section may be circular, oval, square or of other shape.
Instead of the electric furnace, a gas furnace or a heavy oil furnace may be used as the heating furnace. Further, any outer-heat system or inner-heat system or both inner- and outer-heat system may be adopted as a heating chamber.
The invention is illustrated further below with reference to the embodiments of this invention described herein:
The retort 2 in the apparatus shown in FIGS. 2 and 3 having a cylindrical retort is made of stainless SUS 27 of 5cm in diameter and 2m in length. Into this retort is introduced 100 kg of a chromium chloride halide occluded body consisting of chromium chloride (CrCl 2 ) about 20 - 60%, iron (fe) 0.5% or less, aluminum oxide (Al 2 O 3 ) or silicon oxide (SiO 2 ) about 5 - 30% and remaining amount of chromium. Then, argon is supplied to the retort from the feed pipe 5, thereby expelling the air in the retort and then the retort is heated by means of the electric furnace 5. As the heating condition, θ 1 shown in FIG. 3 is determined at 20°- 100°C, θ 2 at 1000°C, (higher than 815°C), the fusing point of chromium chloride, θ 3 at 200°- 400°C (in order to perform further cooling, a cooling means 5' is employed and θ.sub. 3 is sometimes determined at 30° - 100°C) 20 l/min. of argon gas is supplied from the feed pipe 4 and a temperature distribution of the section of the retort inside is made, as shown in FIG. 4. The chromium chloride which is evaporated in the retort is quenched with argon gas to make into fine powders, and thus, the fine powders of anhydrous chromium chloride of 0.5-1μ in diameter and of 99.9% in high purity was obtained.
This invention is carried out as described above, namely, the occluded metal halide body is placed in the heating chamber and is heated to its fusing point or higher; the metal halide is evaporated, dispersed, and then a dried inert gas at low temperature is introduced into the heating chamber. The metal halide which is evaporated and dispersed is quenched and solidified; therefore, the fine powders of metal halide thus obtained can be easily and continuously produced in abundance by skillfully utilizing the evaporating and dispersing action, as well as the cooling and solidifying action. Further, the cooling takes place with the inert gas, so that oxidation can be prevented and fine powders of anhydrous metal halide of high purity can be manufactured.
Further, instead of the inert gas used in the abovementioned illustrative embodiment, a dried mixed gas at low temperature consisting of 80% inert gas (for example, argon or nitrogen gas) and 20% hydrogen sulfide gas, is used; the mixed gas is introduced in the heating chamber from the feed pipe 4 at one end of the retort 2, and chromium sulfide is produced by the reaction of chromium halide which is evaporated in the retort with hydrogen sulfide gas and chromium sulfide is quenched; (in order to perform a further quenching, the retort 2 is sometimes cooled by means of the cooling means 5'); in this manner, chromium sulfide is made into fine powders. Further, it is remarked, that the fine powders of this chromium sulfide are stored in the storage tank 8, which is maintained in a drying condition. The chromium sulfide is introduced from the other end of the retort 2 through the feed pipe 7 with the valve 6 by means of said gas blown in. In this case, therefore, chromium sulfide, suitable as a lubricant, can easily and continuously be produced in abundance by skillfully utilizing the reaction of the chromium halide evaporated and dispersed with the hydrogen sulfide gas evaporated and dispersed, and the quenching and solidifying action by means of feed gas.
As explanation of the invention is made below with reference to FIGS. 5 through 8 in other illustrative embodiments and examples.
EXAMPLE 1
A carbon steel gear is provided, having a chemical composition of C: 0.42%, Mn: 0.68%, Si: 0.21%, P: 0.015% and S: 0.026%. This gear is placed with a chromium chloride generating substance in an atmospheric furnace in which the atmosphere can be controlled from the outside. After the air in the furnace is eliminated, a temperature in the furnace is maintained at 1000°C for 5 hours, chromium is thus cemented on the surface of the gear and thereafter, the gear is at once put in oil and quenched so that hardening of the gear takes place.
Next, as shown in FIG. 5, in the case 12 provided in the electric furnace 11, the quenched gears 14 are immersed for one hour and heated at 200°C in a mixed salt 13 of sodium sulfate (85%) and potash alum (15%). The gears are then aircooled. As shown in FIG. 6, a matrix 15 of tempered martensite, a chromium cementation zone 16 (15μin average thickness), a chromium zone 17 (20μ in average thickness) and a chromium sulfide zone 18 (2μ in average thickness) are produced in turn. The structure of the matrix is illustrated in section by FIG. 6. A wear-proof and a corrosion-proof treated gear of HRC49 in surface hardness was thus obtained.
In similar fashion, another gear consisting of carbon steel of the same composition as described above is heated at 1000°C, and after oil hardening, quenching is performed at 200°C and thus a heat-treated gear of HRC49 in hardness was also obtained.
The two kinds of gears obtained, as described above, are engaged with gears of the same kind respectively without feed oil and are rotated. Then, a wear loss (decreased amount of tooth thickness) of tooth in pitch circle was measured. The test results showed that merely heat-treated gears are inferior in wear resistance, as indicated by line A of FIG. 7, and such a gear has no corrosion resistance. However, a wear- and corrosion-resistant treated gear, according to this invention, is remarkably excellent in wear resistance, as indicated by line B of FIG. 7 and also has corrosion-resistance.
EXAMPLE 2
Chromium cementation gears 14 which are made of carbon steel obtained with the same composition as that of Example 1 are placed in case 12 of electric furnace 11 as shown in FIG. 8. A mixed gas of 70% argon and 30% H 2 S is supplied from gas feed port 21 in lid 20 on which fan 19 is mounted. The air in case 12 is vented from a port hole 22. Thereafter, the gears were taken out after heating at 600°C for one hour.
In this example, too, a chromium sulfide zone is formed on the surface of the chromium zone on the gear and the same wear-resistance and corrosion-resistance, as in the case of Example 1, was obtained.
EXAMPLE 3
After a shaft made of brass is plated (5μin thickness) with chromium, this shaft is reacted with sulfur in mixed salt, as shown in FIG. 1, and thus chromium sulfide (1μin thickness) was produced on the surface.
When this shaft was inserted in the hole of a bearing and was slided reciprocatingly, wear loss was lowered to 1/5 as compared with a shaft made of brass which was not so treated.
Since this invention is constituted as described hereinabove, it has been found that the chromium sulfide has a lubricating property, namely, a wear-resistance is produced on the surface of the chromium zone having corrosion-resistance by merely performing a treatment such as the reaction of the chromium zone in sulfide after the chromium zone was formed on the surface of metal products merely by chromium cementation or chromium plating. In this manner, both wear-resistance and corrosion-resistance of the gears can be improved.
While specific embodiments of the invention have been shown and described in detail to illustrate the application of the principles of the invention, it will be understood that the invention may be embodied otherwise without departing from such principles. | An improved method of making finely divided, dry metal halides and sulfides, such as chromium chloride and chromium sulfide which are suitable for use as lubricants and wear-proof and corrosion-proof agents for metals. | 2 |
FIELD OF THE INVENTION
This invention relates to a method and apparatus for the monitoring of systemic absorption of irrigation fluids during surgery. More particularly, the invention is directed towards the use of an irrigation fluid which has been spiked with ethanol and the detection and measurement of tidal breath alcohol in patients undergoing operative hysteroscopy as a means of determining the occurrence of systemic absorption of irrigation fluids.
BACKGROUND OF THE INVENTION
As Operative Hysteroscopy has gained popularity as a method to treat problems which formerly would have required open abdominal surgery, a number of complications of water and electrolyte imbalance secondary to the absorption of the irrigation fluid used during the procedure have become recognized. 1-5 .
In open abdominal surgery, when irrigation fluids are instilled onto the surgical site, they are typically recovered using a suction apparatus in conjunction with a graduated collection bottle so that the surgeon has a reasonable estimate of the amount of fluid instilled, the amount recovered by suction, and, therefore, the amount of irrigation fluid available for systemic absorption.
In contrast, however, operative hysteroscopy generally requires injection of irrigation fluids under pressure to distend the uterus and because a relatively small opening is utilized during the surgery, the irrigation fluid is recovered as outflow. Because of the necessity of using this method of recovery, the collection and measurement of irritation fluids so injected is inaccurate with some irrigation fluid frequently being lost by absorption into the various drapes and bed linens as well as through spillage. In addition, the instilled irrigation fluid may be admixed with body fluids thereby adding to the apparent volume of outflow fluid. Thus the surgeon frequently has to guess whether or not, and if so, how much fluid is available for systemic absorption by the patient.
Irrigation fluids typically employed in operative hysteroscopy include, by example and not by way of limitation, 3% Sorbitol, Hyscon (comprising 32% Dextran 70 in water) and Saline.
Irrigation fluids are typically refrigerated and administered cold in an attempt to control bleeding.
Apparatus for sampling expired air are well known. Examples of such apparatus are shown in U.S. Pat. No. 2,795,223 to Stampe, U.S. Pat. No. 3,661,528 to Falk, and U.S. Pat. No. 4,297,871 to Wright, et al. Similarly, devices for measuring the alcohol content in exhaled breath, such as that shown in U.S. Pat. No. 4,736,619 to Legrand are also well known.
Similarly, the measurement of tidal alcohol in patients undergoing Transurethral Prostatectomy (TURP) to avoid many of the same complications as has been recognized in Hysteroscopy patients has also been documented. 6-13 Where tidal alcohol has been used as a measurement or indicator of the absorption of irrigation fluid, from 1% to 2% Ethanol by volume is added to the irrigation fluid before it is instilled in the patient.
However, Operative Hysteroscopy is fundamentally different from TURP in that higher injection pressures, on the order of 60-80 mm. Hg are used, and, unlike the TURP patient, if the Hysteroscopy patient has patent fallopian tubes, there is a direct pathway into the peritoneal cavity. In addition, whereas TURP is frequently performed using local anesthesia, such as epidural or spinal anesthesia, Hysteroscopy is frequently performed with the patient "asleep" under general anesthesia.
Accordingly there is need for a means for the detection and measurement of end tidal alcohol in patients who are under general anesthesia to determine the occurrence of the absorption of irrigation fluids.
THE INVENTION
Objects
It is therefore an object of this invention to provide an apparatus which can detect and measure end tidal alcohol in the breath of an anesthetized patient.
It is a further object of this invention to provide an apparatus which can detect and measure end tidal alcohol in the breath of a patient under general anesthesia.
It is another object of this invention to provide a method by which the apparatus described herein can be used to predict the systemic absorption of irrigation fluid at a surgical site
A still further object of this invention is to provide an apparatus which can detect and measure end tidal alcohol in the breath of an anesthetized patient undergoing Operative Hysteroscopy.
A still further object of this invention is to provide a method whereby the presence of end tidal alcohol in the breath of an anesthesized patient may be used as an indicator of the absorption of irrigation fluid during surgery.
Another and still further object of this invention is to provide a method whereby the presence of end tidal alcohol in the breath of an anesthesized patient may be used as an indicator of the absorption of irrigation fluid during operative hysteroscopy.
The novel features of this invention are set forth with particularity in the claims. The invention will be best understood from the following description when read in conjunction with the accompanying drawings and figures.
BRIEF DESCRIPTION OF THE DRAWINGS AND FIGURES
FIG. 1 is a schematic view of an anesthesia gas delivery device and a breath alcohol measurement device connected to a patient under general anesthesia.
FIG. 2 is a plan view in partial cross section of the apparatus and its connection to a tidal alcohol measurement device.
FIG. 3 is a plan view of an alternative embodiment of the invention.
FIG. 4 is a tabular summary of patient data.
FIG. 5 is a graphical presentation of Breath Alcohol Level as a function of time.
DETAILED DESCRIPTION OF THE INVENTION
In the description that follows, like parts are marked throughout the specification and drawings with the same reference numerals, respectively. The drawings are not necessarily to scale and the proportions of certain parts have been exaggerated to better illustrate the details of the present invention.
Referring now to FIG. 1, Patient P has been incubated with an endotracheal tube, E, of a type commonly known in the art. Ported connecting tube 1 is connected in flow registration between endotrachial tube T and flexible gas delivery hose H. Gas delivery hose H is in turn connected in flow registration to the gas outlet port (not shown) of an anesthesia gas delivery device, G, of a type commonly known in the art, such as the Narkomed 2B™ produced by North American Drager of Telford, Pa. Such anesthesia gas delivery machines commonly contain several precision flow meters and metering valves, as well as a bellows type ventilator, canisters of absorbent and patient monitoring apparatus such as blood gas measurement devices and electrocardiogram equipment. Such anesthesia gas machines are designed to be placed intermediate a high pressure source of anesthesia gas and the patient.
Set atop gas delivery device G is a "sniffer-type" breath alcohol vapor concentration measuring device, or meter, M, of a kind commonly known in the art, such as the Alco-Sensor III™ produced by Intoximeters, Inc., St. Louis, Mo. Such sniffer type meters commonly have an internal vacuum producing bellows which, when manually activated, draws a small portion of the exhaled air into the sampling chamber of the device. Except by means of flexible tube T, described below, there is no physical connection between the gas delivery device, G, and the alcohol meter, M, with the device G merely serving as a pedestal or platform upon which meter M is placed.
Meter M is connected to ported connecting tube 1 by means of a flexible tube T in flow registration between the port in connecting tube 1, as described in further detail below, and the sampling inlet of meter M.
Referring now to FIG. 2, ported connecting tube 1 comprises a tube having an interior surface 10 and an exterior surface 20. Said interior surface forms the outer boundary of fluid passage 15. A first opening 30 and a second opening 40 in flow registration with each other and form the ends of said passage 15. Intermediate said first opening 30 and said second opening 40 is flow port 50 which connects said interior surface 10 and said exterior surface 20 thereby forming a flow passage between passage 15 and the exterior of tube 1.
Flow port 50 is sized so that flexible tube T may be inserted therein and its diameter is such that tube T is held in place by a friction fit.
Flexible tube T has a first opening 60 in flow registration with a second opening 70. Second opening 70 is fitted to and in flow registration with Breath Alcohol Meter M, and first opening 60 is in flow registration with passage 15.
Exterior surface 20, proximate first opening 30, is formed to be firmly attached to flexible Gas Delivery Hose H. Proximate to second opening 40, exterior surface 20 is formed to be firmly attached to endotrachial tube T so that passage 15 is in flow registration with the Gas Delivery Hose H and the endotrachial tube T.
Turning now to FIG. 3, in an alternative embodiment, rather than retaining tube T in flow port 50 by means of a friction fit, a connector means 55 having a flow passage therethrough (not shown), shown here by way of an example and not by means of limitation as a screw type fitting, is molded as a part of exterior surface 20. A mating fitting 60 is made up on the end of tube T thereby providing a more secure threaded attachment and therefore providing a more secure flow passage between passage 15 of the ported connecting tube 1 and breath alcohol meter M.
EXAMPLES
Referring now to FIG. 4, results are shown for nineteen (19) patients who have undergone Operative Hysteroscopy.
An AlcoSensor III™ breath alcohol measurement system, sold by Intoximeters, Inc. was attached to the anesthesia circuit as described above and as shown in FIGS. 1 and 2 was standardized according to the supplier's directions.
The patient was incubated with a cuffed endotracheal tube T of a type commonly known in the art. The endotracheal tube T was connected in flow registration with ported connecting tube T, which, in turn, was connected in flow registration with gas delivery hose H. The gas delivery hose H was then connected in flow registration with gas delivery device G.
After the patient was anesthesized with a gaseous general anesthesia agent and surgery had commenced, and irrigation of the surgical site was required, a solution of 1% Ethanol in 3% Sorbitol was used. Once irrigation was commenced, breath alcohol concentration measurements in the end-tidal air of the patient were taken every five (5) minutes to determine if any of the irrigation fluid was being systemically absorbed.
RESULTS
FIG. 4 sets out the patient weight in lbs.; the Scope time, which is the surgery time in minutes; Sorbitol In and Sorbitol Out, is the number of cc's of the irrigation fluid instilled and recovered on outflow, respectively; IV Fluids is the number of cc's of fluid administered intravenously to the patient; Peak EtOH is the maximum quantity of ethanol (expressed as g/100 ml) detected in the patient's expired breath during the surgery; and Pitressen which refers to whether or not the drug Pitressen, also known as vasopressen was administered during the surgery.
A comparison of the columns in FIG. 4 labeled "Sorbitol In" and "Sorbitol Out" shows a discrepancy between irrigant instillation and outflow varied from a loss of 1700 cubic centimeters (cc's) to a net gain of 1100 cc's. This variation illustrates the unreliability of the outflow measurement method as described above.
In the nineteen patients documented in FIG. 4, end--tidal air containing greater than 0.001 g/100 ml EtOH was documented in nine patients. In five patients, the amount of "Sorbitol In" was greater than the amount of Sorbitol recovered (Sorbitol Out) indicating systemic absorption of Sorbitol by the patient at the surgical site. In four patients, the amount of "Sorbitol Out" exceeded the amount of Sorbitol instilled (Sorbitol In) indicating the inclusion of blood or other bodily fluid in the Sorbitol removed from the patient.
Patient 1 had a previously unrecognized uterine peroration which was identified after the surgery commenced. She showed a rapid apparent loss of Sorbitol, but no appreciable level of Ethanol in her expired air. Surgery was rapidly completed with intermittent irrigation.
Referring now to FIG. 5, patient No. 12 showed a breath alcohol level of 0.019 g/100 ml expired air within ten minutes into the procedure. Hahn 10 has shown that a level of 0.025 gm/100 ml corresponds to approximately one liter of systemic absorption of irrigation fluid and probably represents a critical warning level. Thus the procedure was quickly terminated and the patient taken to recovery. Using the outflow method, an estimated 600 ml of irrigation fluid was lost, but due to the inaccuracy of this method, the amount of fluid lost must be considered suspect.
This invention has been described with reference to an exemplary embodiment, however, the foregoing description is not intended to be construed in a limiting sense. Various modifications of the disclosed embodiment as well as alternative applications of the invention will be suggested to persons skilled in the art by the foregoing specification and illustrations. It is therefore contemplated that the appended claims will cover any such modifications, applications or embodiments as fall within the true scope of the invention.
REFERENCES
1. Keith Fleisher, M.D., et al, "Hyponatremia and Possible Uterine Peforation During Endometrial Rollerball Ablation, Anesth. Analg., Vol 77, pp. 860-61 (1993).
2. Joseph D'Agosto, M.D., et al, "Absorption of Irrigating Solution during Hysteroscopic Metroplasty, Anestheology, Vol 72, pp. 379-80 (1990).
3. Allen I. Arieff, M.D., et al, "Endometrial Ablation Complicated by Fatal Hyponatremic Encephaolpathy, J. Am. Med. Assn., Vol. 270, No. 10, pp 1230-32 (1993).
4. Letters: "Hyponatremic Encephalopathy After Endometrial Ablation", J. Am. Med. Assn., Vol. 271, No. 5, pp. 343-44 (1994).
5. Jonathan S. Krohn, M.D., "Dilutional Hypocalcemia in Association with Dilutional Hyponatremia", Anestheology, Vol. 79., No. 5 (1993).
6. Robert Hahn. M.D., et al., "Immediate detection of irrigant absorption during transurethral prostatectomy: case report", Can. J. Anaesth., Vol. 36, No. 1, pp 86-8 (1989).
7. Jan O. Hulten, et al., "Monitoring Irrigating Fluid Absorption During Transurethral Resection of the Prostate (TURP); A Comparison Between 1% and 2% Ethanol As A Tracer, Scand. J. Urol. Nephrol. Vol. 23. pp. 103-08 (1988).
8. R. G. Hahn, M.D., "Prevention of TUR syndrome by detection of trace ethanol in expired breath", Anaesthesia, Vol. 45, No. 7, pp. 577-81 (1990).
9. R. G. Hahn, "Calculation of Irrigant Absorption by Measurement of Breath Alcohol Level during Transurethral Resection of the Prostate", British Journal of Urology, Vol. 68, pp. 390-93 (1991).
10. R. G. Hahn, "Monitoring TURP with ethanol", The Lancet, Vol. 338, p. 1602, (Dec. 21, 1991).
11. Note: "Monitoring TURP", The Lancet, Vol. 338, pp. 606-7, (Sep. 7, 1991).
12. Hans Hjertberg, M.D., et al, "Use of Ethanol as Marker Substance To Increase Patient Safety During Transurethral Prostatic Resection", Urology, Vol. 38, No. 5, pp 423-8 (1991).
13. J. Hulten, et al., "Monitoring of irrigating fluid adsorption during transurethral prostatectomy", Anaesthesia, Vol. 46, pp. 349-53, (1991).
14. Terence M. O'Connor, M.D., "Use of Ethanol--Marked Irrigation Fluid for Operative Hysteroscopy", presented at 1994 Annual Meeting, Society for Ambulatory Anesthesia, Apr. 29, 1994.
15. "Ethanol as a Marker Shows Pulmonary Edema During Hysteroscopy", Anestheology News., July, 1994 at 1. | A ported connecting tube is interposed between the gas delivery hose of an anesthesia gas delivery machine and the outlet of an endotracheal tube. One end of a flexible conduit is inserted into the port in the connecting tube and the other end is connected to a breath alcohol meter thereby placing the sampling chamber of the meter in flow registration with the endotracheal tube. During operative hysteroscopy, a refrigerated solution containing, optimally 1% Ethanol is used to irrigate the surgery site, and the patient's expired breath is periodically sampled to determine the presence and quantity of ethanol therein. The presence of ethanol indicates systemic absorption of the irrigation fluid by the patient, which absorption may cause undesirable operative and post operative complications in the patient. | 6 |
This application is a 371 of PCT/FR2010/000758 filed on Nov. 15, 2010, published on May 19, 2011 under publication number WO 2011/058249 A, which claims priority benefits to French Patent Application 09/05487 filed Nov. 16, 2009, the entire disclosure of which is incorporated herein by reference.
BACKGROUND OF THE INVENTION
The present invention relates to a valve with a rotary stopper and a water-treatment plant comprising such a valve.
The invention relates notably to motorized three-way valves (i.e. with three connection interfaces) and to water-treatment plants for seawater or brackish water by reverse osmosis which incorporate such valves.
In the present application, unless explicitly or implicitly indicated to the contrary, the terms “cylinder” and “cylindrical” refer to a body delimited by—or a shape or a surface engendered by—parallel straight lines resting on a closed contour which may be circular.
DESCRIPTION OF THE PRIOR ART
In plants for desalinating seawater by reverse osmosis, the water to be treated is delivered to the inlet of a filtration device at an inlet pressure that is higher than the osmotic pressure of the water; usually, since the osmotic pressure of salt water is 25 bar, the water supply pressure at the inlet of the filter is at least equal to 25 bar, for example of the order of 30 to 100 bar, in particular of the order of 60 to 80 bar; recovered at the outlet of the filter is a concentrate of water called “brine” on the one hand, and an ultrafiltrate of desalinated water (which is at a pressure close to atmospheric pressure) on the other hand; the pressure of the concentrate at the outlet of the filter is usually not much less than the supply pressure of water to be desalinated, for example less than the supply pressure by a value of the order of 1 to 5 bar, since the pressure drop in the filter is slight.
Patents FR 2342252 and U.S. Pat. No. 4,124,488 describe a plant for purifying water by reverse osmosis comprising a piston pump delivering the pressurized water to the inlet of a reverse osmosis module (ROM) and receiving the pressurized brine leaving the module ROM via a controlled valve, in order to use the energy of the pressurized brine to compress/pressurize the water to be desalinated.
The piston of the pump is driven in an alternating translation movement by an electric motor.
According to one embodiment, a rear portion of the piston has two peripheral longitudinal grooves such that, the piston also being driven in an angular oscillation movement, the piston forms a stopper placing a chamber of the pump extending behind the piston in communication either with a duct for conveying brine originating from the ROM or with a discharge duct.
One drawback of this plant is that causing the piston to oscillate angularly requires causing the pump body to oscillate angularly, which causes an unnecessary consumption of energy. This causing of the pump body to oscillate angularly requires the pump to be connected to the circuits of the plant via flexible connectors, which has implementation problems notably because of the pressure of the water circulating in the plant.
Patents EP 1194691 and U.S. Pat. No. 6,652,741 describe a seawater treatment plant in which several piston pumps are driven by means of a hydraulic actuator and are controlled to ensure a stoppage time of each piston, at each end of stroke of the piston in question, and to ensure a constant total flow rate.
The intake of brine into a chamber of each pump for the recovery of energy from the “concentrate”; and the subsequent discharge of this concentrate, are carried out by a three-way valve or directional-flow valve.
This device, the valve or directional-flow valve, must satisfy several requirements: it must allow the passage of a high flow rate of water without causing considerable pressure losses; it must be designed to withstand the high pressure (of the order of 60 to 80 bar for example) of the brine leaving the osmotic filters; moreover, when no provision is made to stop the pistons of the pumps at the end of the stroke for a sufficient period, this device must then switch from a configuration for taking water into the pump to a configuration for discharging water from the pump, substantially instantaneously, at the precise moment when the pump piston in question stops at the end of the stroke.
The known valves and directional-flow valves do not satisfy these requirements simple and reliably.
SUMMARY OF THE INVENTION
One object of the invention is to propose a valve or directional-flow valve that is simple to manufacture and install, having a long service life and high reliability, causing little pressure loss, making it possible to close in a substantially sealed manner a duct for conveying brine connecting a filtration module to a piston pump and being able to change—“switchover”—, substantially instantaneously, from a configuration of supply in which the valve is traversed by a current of pressurized brine supplying the pump, to a configuration of discharging/emptying in which the valve is traversed by a current of brine discharged from the pump.
One object of the invention is to propose a valve or directional-flow valve that is improved and/or that remedies, at least in part, the shortcomings or drawbacks of the known valves and directional-flow valves.
One object of the invention is to propose a plant for treating seawater or brackish water comprising a pump and a three-way valve for supplying the pump with brine and for discharging the brine, that is improved and/or that remedies, at least in part, the shortcomings or drawbacks of the known water-treatment plants.
According to one aspect, the invention proposes a valve comprising:
a valve body delimiting a cavity, the body being provided/pierced with a first orifice allowing water to enter the cavity, with a second orifice allowing water to be discharged from the cavity, and a third orifice making it possible to place the cavity and a chamber of a pump in communication; a stopper mounted so as to be able to rotate inside the cavity, the stopper comprising a recess on its outer face, this recess helping, with the body to form/delimit a passageway—which rotates with the stopper—allowing water to travel between the first and third orifices in first angular positions of the stopper—corresponding to a configuration of the valve allowing the pump to be supplied—, said passageway also allowing water to travel between the second and third orifices in second angular positions of the stopper—corresponding to a configuration of the valve allowing the pump to be emptied; a first sealing device making it possible to stop in a substantially watertight manner the first orifice by the stopper in said second angular positions of the stopper; and a second sealing device making it possible to stop in a substantially watertight manner the second orifice by the stopper in said first angular positions of the stopper.
Notably when the outer face of the stopper is cylindrical, the recess may take the shape of a groove or flat extending along an axis orthogonal to the axis of revolution/rotation of the stopper, and have a width that is substantially/not much smaller than the diameter of the first and second orifices.
Preferably, in addition to said recess—first recess—said passageway comprises a second recess on the periphery/surface of the stopper, in particular a second recess of substantially annular shape which extends—at least in part—facing the third orifice, and a channel hollowed out in the stopper and connecting said first and second recesses.
The cross section of this channel may be not much smaller, equal or greater, than that of the first and second orifices in order to limit the pressure losses caused by the passage of the water in this channel and consequently in the valve.
In other words, and according to another aspect of the invention, what is proposed is a valve comprising a body delimiting a cavity and pierced with three orifices, and a stopper—or plug—mounted so as to rotate inside the body; the body comprises two housings leading into the cavity and surrounding respectively two of the three orifices; the valve also comprises two sealing members respectively placed slidingly in the two housings, and two pressing devices making it possible respectively to press the two sealing members against the stopper, in order to provide a substantially watertight stopping of a first of the three orifices, by the stopper, in second angular positions of the stopper and in order to provide a substantially watertight stopping of a second of the three orifices, by the stopper, in first angular positions of the stopper—distinct from the second angular positions.
According to a preferred embodiment, the housings take the shape of annular slots and the sealing members have an annular—or tubular—shape adapted to the shape of the portion of the stopper against which they are pressed, in particular a shape cut away like a bevel on a radius corresponding to the radius of a cylindrical portion of the stopper.
Preferably, each of the pressing devices comprises a channel, in particular several channels, which connect(s) one end of the housing in question that is opposite to the end (of the housing in question) that opens into the cavity: the pressing device associated with the sealing member surrounding a first of the orifices comprises at least one channel connecting the non-open end of the housing in question to a sleeve for connecting the valve to a duct conveying the water coming from a filtration module, while the pressing device associated with the sealing member surrounding a second of the orifices comprises at least one channel connecting the non-open end of the housing in question to the cavity.
These channels make it possible to place at equal pressure the non-open end of the housing in question and the duct conveying the water coming from the filtration module, respectively the cavity, and consequently make it possible to press against the stopper the “profiled” end of each of the sliding sealing members, notably when these members have a reduced thickness in their annular portion flush with the surface delimiting the cavity.
Moreover, accordingly, each of the pressing devices may comprise an elastically deformable member, such as a spring, placed in the corresponding housing, between the non-open end of the housing and the end of the corresponding sealing member, in order to keep the stopper and the sealing member in mutual contact when the valve is not operated and when no water current passes through it.
According to other preferred features:
the first and second orifices are facing one another, aligned along an axis that is (substantially) orthogonal to the axis of revolution of the cavity—which corresponds to the axis of rotation of the stopper—, these two axes being (substantially) coplanar; the valve body is pierced with two other orifices—fourth and fifth orifices—which face one another, aligned along an axis that is (substantially) indistinguishable from the axis of revolution of the cavity, and the stopper is secured in rotation to a drive shaft extending through these two orifices.
According to another aspect of the invention, a water-treatment plant is proposed comprising a water-filtration module, a pump with a piston, a motor, a mechanism for the driving of the pump by the motor, and a three-way valve with a rotary plug as described in the present application, the valve being fitted to a duct connecting the pump to the filtration module, the stopper of the valve being rotated substantially continuously by the motor, in synchronism with the pump.
According one embodiment, the stopper is driven so as to rotate one rotation when the piston of the pump makes a complete cycle, i.e. one stroke in one direction and one return stroke.
The continuous rotation of the stopper, usually with a substantially constant rotation speed, and the features of the stopper allowing the valve to switch substantially instantaneously from a supply configuration—for supplying the pump—with pressurized brine to a configuration for discharging the brine, in particular when the respective diameters of the first and second orifices are equal and that the depth of the first recess is equal to the difference between the radius of the stopper—in line with this recess—and the radius of the orifices.
According to one embodiment, the stopper provides a “total” closure of the valve for only two determined angular positions of the stopper: in each of these positions, the stopper closes the passageway between the first and third orifices and the passageway between the second and third orifices—and also the passageway between the first and second orifices.
In other words, according to this embodiment, the first angular positions of the stopper are adjacent so as to form a first continuous angular range of first angular positions of the stopper, which extends substantially over 180° (angle degrees), and the second angular positions of the stopper are also adjacent so as to form a second continuous angular range of second angular positions of the stopper, which also extends over 180°.
Other aspects, features and advantages of the invention will appear in the following description which refers to the appended figures and illustrates, without being in any way limiting, preferred embodiments of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a diagram of a water-treatment plant according to one embodiment of the invention.
FIG. 2 is a schematic view in perspective of a valve according to one embodiment of the invention, of which the stopper is in the closed position of the valve, with partial cutaway: in this figure, as in FIGS. 4 to 6 , all that appears is the portion of the valve body extending under the plane containing the longitudinal axis of the body—and of the rotor—and the axis passing through the centers of the first and second orifices, the other portion of the body extending above this plane being “cut away” (not shown) in order to make it possible to view the rotor of the valve.
FIG. 3 is a schematic view in perspective of the rotor—including the stopper—of the valve illustrated in FIGS. 2 and 4 to 11 .
FIGS. 4 to 6 are schematic views in perspective similar to FIG. 2 , which show the rotor of the valve in other angular positions.
FIG. 7 is a view in longitudinal section of the valve along a first sectional plane containing the axis of two sleeves for connecting the valve to a filtration module—for one of the sleeves—and to a discharge circuit—for the second sleeve.
FIG. 8 is a view in longitudinal section of the valve along a second sectional plane perpendicular to the first and containing the axis of a third sleeve for connecting the valve to a piston pump.
FIG. 9 is a view in cross section of the valve along a third sectional plane perpendicular to the first two and containing the axis of the third connecting sleeve: this figure is a view along IX-IX of FIG. 7 .
FIG. 10 is a view in longitudinal section along the first sectional plane illustrating, on an enlarged scale, the sleeve for connecting the valve of FIGS. 2 and 4 to 11 to the discharge circuit.
FIG. 11 is a view in longitudinal section along the first sectional plane illustrating, on a larger scale, the sleeve for connecting the valve of FIGS. 2 and 4 to 11 to the filtration module.
FIG. 12 is a view in section along the first sectional plane illustrating, on a larger scale, another embodiment of the sealing device fitted to the sleeve for connecting the valve to a filtration module.
DETAILED DESCRIPTION OF THE INVENTION
Unless explicitly or implicitly indicated to the contrary, elements or members that are—structurally or functionally—identical or similar are indicated by identical references on the various figures.
With reference to FIG. 1 , the water-treatment plant comprises a water-filtration module 15 , a piston pump 27 , an electric motor 10 , a mechanism 11 for driving the pump via the output shaft 30 of the motor, and a three-way valve 24 with rotary plug.
The pump 27 comprises a body 13 delimiting a cylindrical cavity 16 , 17 inside which the piston 14 of the pump is driven in alternating translation 28 , the piston separating the cavity into two chambers: a first chamber 16 receiving the brine discharged from the module 15 , and a second chamber 17 receiving the water to be pumped and to be delivered under pressure to the module 15 .
The piston 14 is connected by a rod 12 to the mechanism 11 .
The pump 27 receives the water to be pumped delivered by a water-conveying duct 18 fitted with an inlet valve element 19 (nonreturn valve element).
The water pressurized by the pump 27 is conveyed to the module 15 by a duct 20 fitted with a delivery valve element 21 (nonreturn valve element).
The water (fresh water) filtered by the module 15 leaves the latter through a duct 22 , while the brine is conveyed by a duct 23 fitted with the valve 24 , from the module 15 to the “energy recovery” chamber 16 of the pump 27 .
The valve 24 is also connected to a duct 25 through which the brine is discharged from the chamber 16 at the end of each compression stroke of the piston 14 of the pump 27 during the stroke—in the reverse direction—of the piston 14 allowing the chamber 17 to be filled by the water to be pumped.
The transition from one configuration of the valve 24 allowing the passage of the brine originating from the module 15 to the chamber 16 , to a configuration of the valve allowing the discharge of the brine from the chamber 16 , results from the rotation 29 of the plug—i.e. of the stopper—of the valve.
The substantially continuous rotation of the stopper of the valve results from the driving of the stopper by the motor, in synchronism with the pump, by means of a shaft 26 for driving the stopper, this shaft 26 being connected for this purpose to the mechanism 11 .
With reference to FIGS. 2 and 4 to 9 , the valve 24 comprises a body 40 delimiting a cavity 41 .
The body 40 comprises a tubular central part 42 extending along an axis 43 , two circular flanges 44 and 45 placed and attached—by welding for example—at the two longitudinal ends of the central part 42 , and two parts 46 and 47 respectively attached to the flanges 44 , 45 by screws (not shown) for example.
Each part 46 , 47 is in the form of a thick disk and has a circular central orifice; a shaft 48 with an axis 43 extends through these two bored orifices, this shaft being secured in rotation to the stopper or plug 49 of the valve.
The body 40 also comprises two parts 50 and 51 respectively attached to the parts 46 , 47 by screws (not shown), each part 50 , 51 being in the form of a thick disk, with an external diameter smaller than that of the parts 46 , 47 and having a central circular orifice aligned with those of the parts 46 , 47 and through which the shaft 48 extends.
The tubular collar 42 of the body is pierced with three circular orifices: a first orifice 60 allowing water to be inserted into the cavity 41 , a second orifice 61 allowing water to be discharged from the cavity, and a third orifice 62 making it possible to place the cavity 41 and the chamber (reference 16 , FIG. 1 ) of the pump in communication.
For the connection of the valve to the duct (reference 23 , FIG. 1 ) conveying the brine originating from the filter 15 , the body comprises a first tubular sleeve 63 extending in line with the orifice 60 .
For the connection of the valve to the duct (reference 25 , FIG. 1 ) for discharging the brine, the body comprises a second tubular sleeve 64 extending in line with the orifice 61 .
For the connection of the valve to the duct (reference 23 , FIG. 1 ) for conveying the brine between the valve and the pump, the body comprises a third tubular sleeve 65 extending in line with the orifice 62 .
It can be seen in FIGS. 7 to 9 that each of these three sleeves is attached to the tubular part 42 by a first of its ends, for example by welding, and is furnished with a connecting flange 66 close to its second end.
The sleeves 63 and 64 are coaxial: they extend along an axis 67 perpendicular to the axis 43 and intersecting the latter; the sleeve 65 extends along an axis 68 which is also perpendicular to the axis 43 and intersects the latter, the axes 67 and 68 being orthogonal without being secant.
With reference to FIGS. 2 to 6 in particular, the rotor 70 of the valve comprises a central portion forming the plug 49 and two end portions extending on either side of the plug and forming two shaft ends 48 ; these three coaxial portions, with an axis 43 , can form a single part obtained by machining of a metal blank, for example, or else may consist of several parts fixed together.
It can be seen in FIGS. 2 and 4 to 8 that the stopper 49 is mounted so as to be able to rotate inside the cavity 41 of the valve body; accordingly, the rotor 70 is mounted in the bearings formed in the parts 46 , 47 , 50 , 51 by means of two rolling bearings 71 , 72 (ball bearings for example) fitted onto bearing surfaces formed by the shaft 48 .
With reference to FIGS. 2 to 6 in particular, the stopper consists essentially of a first portion 73 delimited by a cylindrical casing with an axis 43 and a radius 75 (see FIG. 9 ), and of a second cylindrical portion 74 with an axis 43 and radius 76 (see FIG. 8 ) which extends from the first portion 73 .
The radius 75 of the portion 73 is chosen to be slightly less than the radius 80 (see FIG. 8 ) of the cavity 41 , for example smaller than the latter by the order of 0.1 millimeter (mm) when the radius 80 is of the order of 100 mm, so as to define a very slight clearance between the peripheral surface of the portion 73 of the stopper and the wall 42 delimiting the cavity 41 .
The radius 76 of the portion 74 is chosen to be smaller than the radius 80 of the cavity 41 , for example close to the radius common to the orifices 60 to 62 , so that the portion 74 delimits with the wall 42 an annular space 79 —or second recess—allowing water to enter the valve—or leave the latter—through the orifice 62 ; for this purpose, the portion 74 of the stopper—and the volume 79 —preferably extend over a length at least equal to the diameter of the orifice 62 which opens into the volume 79 .
As illustrated notably in FIGS. 2 to 4, 7 and 9 , the portion 73 of the stopper 49 comprises a recess 77 on its outer cylindrical face 90 .
This recess in the form of a groove or flat extends along an axis 91 orthogonal to the axis 43 of revolution/rotation of the stopper, and has a width 92 slightly smaller than the diameter of the first and second orifices 60 , 61 .
The depth 81 of the first recess 77 is substantially equal to the difference between the radius 75 of the stopper—in line with this recess—and the common (identical) radius of the orifices 60 , 61 .
The recess 77 helps—with the body—to delimit a passageway—which rotates with the stopper—allowing water to travel between the first and third orifices in the first angular positions of the stopper, which corresponds to a configuration of the valve illustrated in FIG. 4 and allowing the pump to be supplied.
Accordingly, a channel 78 is formed in the stopper and connects the recesses 77 and 79 as illustrated in FIGS. 2 to 4 and 7 in particular.
The cross section of this channel 78 is preferably at least close to that of the first and second orifices 60 , 61 and/or of that of the groove 77 , in order to limit the pressure losses caused by the water entering the valve.
The passageway formed by the recesses 77 , 79 and by the channel 78 also allows water to travel between the second and third orifices 61 , 62 in second angular positions of the stopper—corresponding to a configuration of the valve allowing the pump to be discharged—which are illustrated in FIGS. 6 and 9 in particular.
The valve also comprises two sealing devices making it possible respectively to achieve a substantially water-tight stopping of the first orifice 60 by the stopper in said second angular positions of the stopper, i.e. in the discharge position, and to ensure a substantially watertight stopping of the second orifice 61 by the stopper in said first angular positions of the stopper, i.e. in the position of supplying the pump with water.
Accordingly, as illustrated in FIGS. 10 and 11 , the body comprises two housings opening into the cavity 41 and surrounding respectively the two orifices 60 , 61 , and two sealing members respectively placed slidingly in the two housings.
A bush 93 , 94 is fitted respectively into each of the sleeves 63 , 64 with the axis 67 .
With respect to the sleeve 63 , in FIG. 11 , an outer cylindrical face 95 of the bush 93 extends coaxially to an inner cylindrical face 96 of the sleeve 63 , facing the latter, so as to delimit a housing 97 receiving a sliding sealing ring 98 and a seal 99 .
With respect to the sleeve 64 , in FIG. 10 , an outer cylindrical face 101 of the bush 94 extends coaxially to an inner cylindrical face 102 of the sleeve 64 , facing the latter, so as to delimit a housing 103 receiving a sliding sealing ring 104 and a seal 105 .
The housings 97 , 103 take the form of annular slots and the sealing members 98 , 104 have an annular—or tubular—shape adapted to the dimensions of the housings and to the shape of the portion of the stopper against which they are pressed: each sealing ring 98 , 104 has, at its end 110 , 111 being flush in the cavity 41 , a shape that is cut away according to a radius corresponding to the radius of the cylindrical portion 73 of the stopper.
A pressing device makes it possible to press the sealing ring 98 against the stopper, in order to ensure a substantially watertight stopping of the first orifice 60 , by the stopper, in angular positions of the stopper in which no portion of the groove 77 is facing this orifice.
A similar pressing device makes it possible to press the sealing ring 104 against the stopper, in order to ensure a substantially watertight stopping of the second orifice 61 , by the stopper, in angular positions of the stopper in which no portion of the groove 77 is facing this orifice.
Each of the pressing devices comprises several channels which connect one end (of the housing in question) that is opposite to the end of the housing in question that opens into the cavity, upstream—with reference to the direction of flow of the water in the valve—of the orifice in question: the pressing device associated with the sealing member 98 surrounding the first orifice 60 comprises four channels 100 distributed angularly about the axis 67 , each connecting the non-open end of the housing 97 to the inner face of the bush 93 of the sleeve 63 .
Similarly, the pressing device associated with the sealing member 104 surrounding the second orifice 61 comprises four channels 106 distributed angularly about the axis 67 and parallel with the latter, which are formed inside the sleeve 64 and each link the non-open end of the housing 103 to the cavity 41 .
The channels 100 make it possible to place the non-open end of the housing 97 and the duct conveying the water coming from the filtration module at equal pressure.
The channels 100 consequently make it possible to press against the stopper 49 the “profiled” end of each of the sliding sealing member 98 , because of the difference between the water pressures that are applied to the two opposite ends of the member 98 .
Similarly, the channels 106 make it possible to place the non-open end of the housing 103 and the cavity 41 at equal pressure and consequently make it possible to press the “profiled” end of each of the sliding sealing member 104 against the stopper, because of the difference between the pressures that are applied to the two opposite ends of the member 104 .
In the embodiment illustrated in FIG. 12 , the sealing member 98 comprises a first annular portion 980 having a first thickness 981 and of which one end is flush with the surface of the body delimiting the cavity 41 .
The member 98 comprises a second annular portion 982 coaxial with—and extending—the first annular portion 980 .
This second portion, which extends facing—and in the vicinity of—the non-open end of the housing 97 and of the channels 100 , has a thickness 983 greater than the thickness 981 so that the ring 98 is pushed back toward the stopper when its two longitudinal ends are subjected to the same pressure.
In order to prevent (or limit) water getting into the interstices extending between the ring 98 and the housing 97 in which the ring can slide, each of the annular portions 980 , 982 of the ring is furnished with an annular housing—like that referenced 984 —receiving a sealing-ring member (not shown).
Moreover, an elastically deformable member 120 , in the form of a ring forming a spring, is placed in the housing 97 receiving the ring 98 , between the non-open end of the housing 97 and the end of the portion 982 of the ring 98 .
The elastic ring 120 is arranged to keep in mutual contact the stopper 49 and the end 110 of the sealing ring 98 when the valve is not operated and/or when no water current passes through it. | The invention relates to a valve ( 24 ) comprising: a body ( 40 ) defining a cavity and provided with a first opening ( 60 ) that makes it possible to feed water into the cavity, a second opening that makes it possible to discharge water from the cavity, and a third opening that makes it possible to connect the cavity ( 41 ) with a chamber; a stopper ( 49 ) that is rotatable inside the cavity, the stopper comprising a depression ( 77 ) on the outer surface ( 90 ) thereof that contributes to the definition of a passage enabling the flow of water between the first and third openings in first angular positions of the stopper and moreover enabling the flow of water between the second and third openings in second angular positions of the stopper, a sealing device that makes it possible to ensure a sealed stopping of the first opening ( 60 ) by means of the stopper in said second angular positions of the stopper; and a second sealing device that makes it possible to ensure a sealed stopping of the second opening by means of a stopper in said first angular positions of the stopper. | 5 |
BACKGROUND OF THE INVENTION
The present invention relates to a control apparatus for a magnetic floating type rotor supported by an electromagnetic bearing. More particularly, it relates to an electromagnetic bearing control apparatus which is well suited to suppress a resonance amplitude of the unbalance vibration of a rotor.
The schematic setup of a rotary machine supported by an electromagnetic bearing, in which attractive electromagnets are used for bearing, is as shown in FIG. 1. First, an apparatus which performs a unidimensional position control in only an X-axial direction will be described.
Coils 2 of electromagnets are arranged on the right and left of a rotor 1. When the rotor 1 shifts rightwards under this state, a control current I flows through the left electromagnet coil 2, and the rotor 1 undergoes an attractive force so as to be displaced leftwards. To the contrary, when the rotor 1 shifts leftwards, a control current I flows through the right electromagnet coil 2 so as to establish an attractive force. In this manner, the control current I is caused to flow through the electromagnet coil 2 on the opposite side in accordance with the rightward or leftward displacement of the rotor 1, to perform a servo control so that the rotor 1 may come to its central position owing to the resulting attractive force.
In this case, at least one displacement sensor 3 is necessary for detecting the righward and leftward displacements of the rotor 1. Often employed as the displacement sensor 3 are e.g.; noncontacting sensors of the induction coil type, capacitance type, optical type, etc.
A displacement signal x detected by the displacement sensor 3 is applied to a control circuit 4, which determines a control voltage v in accordance with the rightward or leftward deviation of the rotor 1 from the central position. The control voltage v is applied to either of power amplifiers 5 for the right and left electromagnet coils, and the control current I proportional thereto flows through the coil 2. The way of applying the control voltage v to the power amplifier 5 of the right or left coil is such that the self-centering effect of the rotor 1 is produced by the attractive force of the electromagnet coil 2.
As thus far described, the servo circuit for the position control of the rotor 1 in the X direction is constructed of the single displacement sensor 3, the two right and left electromagnet coils 2 as well as the corresponding power amplifiers 5, and the single control circuit 4. In general, the position control of the rotor 1 by the magnetic bearing requires two-dimensional position controls in X- and Y-directions as shown in FIG. 2. Therefore, the servo circuits of the same specifications are juxtaposed as two sets for the X direction and for the Y direction.
In FIG. 2, portions having the same functions as in FIG. 1 are indicated by the same symbols.
Next, the features of the vibrations of a rotation axis will be explained. For elucidating the unbalance vibration, FIG. 3 is often used. It is assumed that the axis O r of the rotor 1 lie at a displacement (χ, y) as viewed from a space fixed axis O-XY system. The position of the center of gravity G of the rotor 1 as viewed from a rotating axis O r -X r Y r system fixed to the rotor 1 is assumed (ε.sub.χ, ε y ). Letting Ω denote the rotating speed of the rotor 1, an angle defined between the OX-axis is a rotational angle which is expressed by Ωt (t; time).
When such symbols are assigned, forces acting on the rotor 1 due to unbalance are as follows:
F.sub.χ =mε.sub.χ Ω.sup.2 cos Ωt in the X direction
F.sub.y =mε.sub.y Ω.sup.2 sin Ωt in the Y direction (1)
where m denotes the mass of the rotor. They are indicated on a complex plane of F≡F.sub.χ +iF y (where i: imaginary unit) as follows:
F≡F.sub.χ +iF.sub.y =mεΩ.sup.2 e.sup.iΩt ( 2)
where ε=ε.sub.χ +iε y
Thus, they form a force rotating in the same direction as that of the rotation of the rotor, that is, a forward force.
On the other hand, the vibration of the rotor 1 is detected in the X and Y directions, and the vibration frequency agrees with the rotating speed Ω, so that the vibration is expressed by the following forms:
χ=a.sub.χ cos (Ωt-θ.sub.χ) in the X direction
y=a.sub.y cos (Ωt-θ.sub.y) in the Y direction (3)
Here, amplitudes in the X and Y directions are respectively denoted by a.sub.χ and a y , and phase delays viewed from the rotational angle Ωt are respectively denoted by θ.sub.χ and θ y . When the components of the vibration are indicated on a complex plane as in the above, the locus of the axis becomes an elliptical orbit as depicted in FIG. 4(a). Since θ y -θ.sub.χ <180° holds here, the sense of the orbit is forward as indicated by an arrow similarly to the rotating direction Ω.
When a supporting rigidity based on the electromagnets through the servo control circuit in the X direction is equal to the same in the Y direction, namely, when the supporting rigidities of the bearing in the X direction and the Y direction are set to be isotropic, the vibration amplitudes in the X direction and the Y direction are equal to each other. Moreover, the phase difference between both the vibration components is 90°, and the X-directional vibration leads the Y-directional vibration by 90°. These are expressed by the following equations:
a.sub.χ =a.sub.y, θ.sub.y =θ.sub.χ +90°(4)
These are a natural result for the reason that the unbalance force F acting on the rotor is isotropic in the X and Y directions as indicated by Eq. (2) and that the characteristics of the bearing to receive the unbalance force are also isotropic. The rotor vibration at this time is expressed as follows:
χ=a cos (Ωt-θ) in the X direction
y=a sin (Ωt-θ) in the Y direction (5)
These become a circular motion as shown in FIG. 4(b) when observed as the locus of the rotor bearing similarly on a complex plane. The sense of the orbit is the same as that of the rotating speed Ω and is therefore forward.
As stated above, the rotor vibration becomes the circulr motion for the equal supporting rigidities of the bearing and becomes the elliptic orbit in the presence of anisotropy. The senses of the orbits are the same as the sense of the rotor rotation and are forward. Therefore, when a complex displacement Z indicated by the following equation is introduced:
Z=χ+iy (6)
the rotor vibration is expressed in the following complex forms:
Z=ae.sup.iΩt for isotropic characteristics (7)
Z=a.sub.f e.sup.iΩt +a.sub.b e.sup.-iΩt for anisotropic characteristics (8)
where a, a f and a b are complex numbers expressing complex amplitudes respectively, and the following holds:
|a.sub.f |>|a.sub.b |
In the case of the electromagnetic bearing support, it is generally true that the characteristics are sometimes anisotropic at low-speed rotations, but that they are more isotropic at higher-speed rotations owing to inertia. p An example of an unbalance vibration response curve is shown in FIG. 5. The two peaks M 1 and M 2 of the vibration amplitude on the lower side of the rotational speed are resonance points in the rigid body mode of the rotor. The third peak M 3 of the vibration amplitude is a resonance point in the bending mode of the rotor. Regarding the conventional rotor supported by the magnetic bearing, the resonance points of the rigid body mode at low speed can be passed with their amplitudes suppressed by the adjustments of the proportional action, differential action and integral action of the servo control circuit. The resonance point of the bending mode of a high-speed rotation, however, is inevitably passed with a sharp and large amplitude on account of an insufficient damping force. It is, rather, common that the rotor cannot be operated in excess of a rotational speed corresponding to the bending mode resonance point because the resonance amplitude of the bending mode cannot be suppressed even when those of the rigid body mode can be suppressed by skillfully adjusting the servo control circuit.
A servo control circuit for passing such a resonance point of the electromagnetic type rotor with the resonance amplitude suppressed is described in detail in Japanese Patent Provisional Publication No. 93853/'77. In order to grasp the published invention, the principle of a tracking filter synchronous with a rotational speed, which has been known, and a method of controlling high damping impartation with the tracking filter will be described in divided stages.
The general features of the rotor vibration in the case where the rotor is rotating in a high-speed rotation region will be explained in conjunction with FIG. 2. It is assumed that the rotor be rotating near the bending mode resonance point M 3 shown in FIG. 5. As the rotor vibration on this occasion, the forward vibration synchronous with the rotational frequency attributed to the unbalance is the principal component, and besides, the fluctuating vibration of the rotor attributed to external forces such as the shaking of a casing develops. The vibration frequency of the fluctuating vibration is close to the natural frequency of the rigid body mode and is lower than the rotational frequency. Therefore, the amplitude Z of the rotor vibration is written in the following complex from by applying the aforementioned equation (7):
Z.sub.in =(fluctuating vibration)+ae.sup.iΩt ( 9)
FIG. 6 is a schematic arrangement diagram of a tracking filter for elucidating the operating principle thereof. When the amplitude Z in is input, the output Z out of the tracking filter becomes a signal of only the component synchronous with the rotational speed:
Z.sub.out =ae.sup.iΩt ( 10)
In addition, the input signal Z in is transformed into a rotating coordinate system when multiplied by e -i Ωt by means of a multiplier unit 10. That is:
Z.sub.1 ≡e.sup.-iΩt Z.sub.in =(fluctuating vibration)×e.sup.iΩt +a (11)
and the component a synchronous with the rotational speed becomes a D.C. component in the signal Z 1 of the rotating coordinate system. Besides, as seen from the first term of the above equation, the component having appeared as a low frequency in the fixed coordinate system Z in turns into a high frequency component in the rotating coordinate system Z 1 .
Here, the signal Z 1 is passed through a low-pass filter 11 in order to extract the D.C. component a synchronous with the rotational speed. The output Z 2 of the filter is:
Z.sub.2 ≈a (12)
The cutoff frequency of the low-pass filter is much lower than the rotational frequency. It is usually set at several Hz or a still lower value of approximately 0.1 Hz. The gain of this low-pass filter is 1 (one).
Subsequently, the signal Z 2 of the rotating coordinate system is multiplied by e i Ωt by means of a multiplier unit 20 in order to inversely transform it into the fixed coordinate system. As a result, the output signal Z out is obtained which is such that only the component synchronous with the rotational frequency is extracted from within the input signal Z in as indicated by Eq. (10).
The above is the principle of the filter for the component synchronous with the rotational speed. The filter is called the tracking filter when it follows the rotational speed Ω. e i Ωt is achieved by a process in which a cosine or sine function synchronous with the rotational speed is operated with a matrix. This mathematical principle is generated in the circuit in FIG. 7. In this figure, numeral 9 designates a generator which receives rotation pulses and generates sin and cos waves synchronous with them. Inputs χ in and y in (Z in =χ in +iy in ) are subjected to a matrix operation T by an operation unit 15, to obtain χ 1 and y 1 (Z 1 =χ 1 +iy 1 ): ##EQU1## Thereafter, χ 1 and y 1 are passed through low-pass filters 17 and 18 independently of each other, to obtain χ 2 and y 2 (Z 2 =χ 2 +iy 2 ). Further, these signals are subjected to the inverse transform of the transform T by a transposed-matrix operation unit 19, to find χ out and y out (Z out =χ out +iy out ): ##EQU2## In this way, only the rotation-synchronous components can be extracted from within the χ displacement signal and y displacement signal by the actual electronic circuit.
Next, the resonant amplitude reduction method employing this tracking filter synchronous with the rotational speed as described in Japanese Patent Provisional Publication No. 93853/'77 will be described with reference to FIG. 8.
It is assumed that the displacements of the rotor in the X direction and the Y direction have been detected as χ and y. The circuit is of a feed system wherein, when the displacement signals χ and y are input to proportion-plus-differential circuits 6 and 16, outputs aχ+bχ and ay+by are provided, respectively. The X-directional output signal aχ+bχ and Y-directional output signal ay+by thus derived are input to the tracking filter 7 synchronous with the rotational speed as described above.
The first process in the tracking filter is a transformation into the rotating coordinate system based on the following equation: ##EQU3## By the second process, signals are passed through low-pass filters of gains K (corresponding to the operation of integrating narrow bands) to obtain the signals χ 2 and y 2 . The second process performs filtering operations for the X and Y directions separately from each other. By the third process, the output signals χ 0 and y 0 are obtained through the inverse transform into the fixed coordinate system: ##EQU4## The output signals χ 0 and y 0 are such that, in the vibration waveforms of the input signals χ and y, only the components synchronous with the rotational speed have been extracted. By adjusting the magnitudes of the coefficients a and b of the proportional-plus-differential circuits 6 and 16 or the value of the gain K of the low-pass filter, the operations of advancing the phases of the rotational speed-synchronous components of the signals χ and y can be afforded. That is, the actions of damping the resonance amplitudes can be achieved.
In the critical frequency damping equipment shown in FIG. 8, for the purpose of reducing the resonance amplitude in the X direction by way of example, the χ displacement signal is input to the control circuit 4, while at the same time the χ 0 signal with only the rotation-synchronous component extracted from within the above χ displacement signal through the tracking filter 7 is used for the servo control. The same applies to the Y direction. By utilizing the x 0 and y 0 signals for the servo control, the components synchronous with the rotational speed can be endowed with the phase advance characteristics through the adjustments of the coefficients a and b or the gain K. Thus, the rotor is given the damping action, and the resonance points as shown in FIG. 5 can be passed with smaller amplitudes as indicated by a broken line.
Such a control system, however, has the disadvantage that the velocity signals (χ, y) need to be created from the displacement signals (χ, y) by the proportional-plus--differential circuits 6 and 16, so the circuit arrangement becomes complicated.
The essence of this system is as stated below. The velocity signals χ and y are created from the detected displacement signals χ and y through the differential circuits, and the displacement signals and the velocity signals are passed through the tracking filter 7 synchronized with the rotational speed. Thus, only the rotation-synchronous components of the displacements and velocities are extracted so as to be supplied for the control of only the unbalance vibration components thereof. The bearing rigidity can be adjusted in accordance with the magnitudes of the displacement components, while the bearing damping can be adjusted in accordance with the magnitudes of the velocity components.
SUMMARY OF THE INVENTION
An object of the present invention is to provide a control apparatus for an electromagnetic bearing in which the resonance amplitude of the rotational speed-synchronous unbalance vibration of a rotor supported by the electromagnetic bearing is reduced.
In the control apparatus for an electromagnetic bearing according to the present invention, the channels of an X-direction control circuit and a Y-direction control circuit are crossed to enhance stability against a forward characteristic frequency. In order to solve the problem that stability against a coexisting rearward characteristic frequency is reduced without any measuring, a tracking filter synchronized with a rotational frequency is jointly used. Thus, the enhancement of the stability is permitted against only the forward characteristic frequency near a resonance point, whereby the resonance amplitude of the unbalance vibration can be reduced.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a diagram for explaining the servo control operation of an electromagnetic bearing in the prior art;
FIG. 2 is a diagram of the servo circuit arrangement of a rotor supported by an electromagnetic bearing in the prior art;
FIG. 3 is a dynamic model diagram showing the displacement and unbalance of the rotor in a prior art;
FIGS. 4(a) and 4(b) are diagrams each showing the shaking locus of the axis of a rotor under an unbalance vibration in the prior art;
FIG. 5 is a diagram showing unbalance vibration response curves in the prior art and in the present invention;
FIG. 6 is a diagram for explaining the principle of a known filter synchronized with a rotational speed;
FIG. 7 is a circuit arrangement diagram of a prior-art tracking filter synchronized with a rotational speed;
FIG. 8 is a block diagram of a prior-art device for damping a critical frequency;
FIG. 9 is a block diagram showing an embodiment of a servo control system according to the present invention;
FIG. 10 is a block diagram of a servo control system based on an embodiment of the present invention in the case of anisotropic supporting characteristics; and
FIG. 11 is a graph of test data in the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
In a rotor supported by plain bearings, it is known that a self-excited vibration called `oil whip` develops. The causes will be considered. The reaction of an oil film in the plain bearing is expressed with respect to the displacement and velocity of the rotor, as follows:
F.sub.102 =k.sub.χχ x+k.sub.χy y+c.sub.χχ x+c.sub.χy y
F.sub.y =k.sub.yχ χ+k.sub.yy y+c.sub.yχ χ+c.sub.yy y (17)
where
F.sub.χ, F y : reaction forces of the bearing in X and Y directions,
k ij (i, j=χ, y): elastic constant of the oil film of the plain bearing,
c ij (i, j=χ, y): damping constant of the oil film of the plain bearing.
Conceptually speaking, the constants k.sub.χχ and k yy or those c.sub.χy and c y χ act as bearing rigidities. In addition, since the constants c.sub.χχ and c yy act to damp the bearing, they exert the action of stabilizing the rotor. Meanwhile, the constants k.sub.χy and k y χ indicate the crossing terms of the X and Y directions and form causes for rendering the rotor vibration unstable. Particularly at a rotational frequency for which k.sub.χy >0 and k y χ <0 holds, the forward unstable vibration called the oil whip arises in the rotor. That is, stability against a forward characteristic frequency is reduced, and the damping action decreasing. Since the plain bearing is a passive element, the sign of the constant cannot be changed, and an action in the reverse direction cannot be produced.
With an electromagnetic bearing, however, the sign can be reversed by the arrangement of an electronic circuit so as to produce the action in the reverse direction, namely, the damping action. That is, when the channels of an X-direction control circuit and a Y-direction control circuit are crossed so as to establish k.sub.χy <0 and k y χ >0, the stability against the forward characteristic frequency can be enhanced. In addition, according to such crossing of the channels, stability against a coexisting rearward characteristic frequency is reduced.
Therefore, the rotation-synchronized tracking filter described above is jointly used, whereby the enhancement of the stability becomes possible as to only the forward characteristic frequency near a resonance point. Also, the stability against the rearward characteristic frequency remains unchanged and is not reduced.
In this manner, using both the channel crossing and the rotation-synchronized tracking filter, the enhancement of the characteristic frequency stability or damping capability is achieved as regards only the forward component. An unbalance vibration is a forward force, and the resonance peak thereof to be induced can be reduced to a smaller resonance amplitude as the damping of the forward characteristic frequency is greater.
Now, an embodiment of the present invention will be described with reference to FIG. 9. A displacement signal χ detecting the displacement of a rotor in an X direction is input to a control circuit 4, the calculated result of which is applied to a power amplifier 5 so as to cause a control current i n to flow through an electromagnet 2. The same applies to a Y direction. Such a setup is the basic setup of a servo control system based on an electromagnetic bearing as illustrated in FIG. 2.
The detected displacement signals χ and y are input to a tracking filter 7 for components synchronous with a rotation speed, to extract only the rotation-synchronous components χ n and y N in the displacement vibration components of the rotor. When the bearing is isotropic, the unbalance vibration thereof Z N =χ N +iy N becomes:
Z.sub.N =a·e.sup.iΩt (18)
as indicated in Eq. (7). That is,
χ.sub.N =a.sub.N cos (Ωt-θ.sub.N)
y.sub.N =a.sub.N sin (Ωt-θ.sub.N) (19)
where a=a N e i θ N holds.
Also, the following relations hold:
χ.sub.N =-Ωy.sub.N y.sub.N =+Ωχ.sub.N (20)
This concerns the fact that the unbalance vibration becomes a circular orbit as shown in FIG. 4(b) and proceeds in the same direction as the rotation from an X-axis to a Y-axis. With such a circular orbit, a vibration 90° ahead of the χ vibration is predicted to be the y vibration, and a vibration 90° ahead of the y vibration is predicted to be the -χ vibration. Since this prediction signifies a differential operation, the above equations are physically comprehensible.
When note is taken of only the unbalance vibration components, Eqs. (20) hold, and hence, the output signals χ N and y N of the tracking filter 7 may be respectively regarded as differential signals y N and -χ N . Therefore, in order to afford a damping action in the Y direction, the χ N signal is multiplied by α, and the product is additively input to the Y-direction channel. On the other hand, in order to afford a damping action in the X direction, the y N signal is multiplied by -α, and the product is subtractively input to the X-direction channel. In FIG. 9, the multiplication by -α is indicated as a subtractive input in the X direction.
In this manner, the additive and subtractive inputs are applied crossing the channels, whereby reaction forces for the components synchronous with the rotational speed are expressed as:
F.sub.χ =-αy.sub.N ≡k.sub.χy y (21)
F.sub.y =+αx.sub.N ≡k.sub.yχ χ (22)
This corresponds to the fact that k.sub.χy <0 and k y χ >0 are set. Therefore, the goal of enhancing the damping capability for the forward vibration of the rotor is accomplished.
The coefficient α which is used for the additive and subtractive inputs in the channel crossing, provides an improved damping effect. Since, however, there is the restriction of preventing the saturation of the electronic circuit, the gain may be adjusted so as to establish an appropriate value of the resonance amplitude.
FIG. 10 shows a circuit arrangement well suited to the general case where the characteristics of the bearing are anisotropic to give rise to the unbalance vibration as illustrated by the elliptic orbit in FIG. 4(a) or by Eq. (8).
In this case, the method of suppressing the forward vibration a f e i Ωt of Eq. (8) is the same as in the preceding case of FIG. 9. The method of suppressing the rearward vibration component a b e -i Ωt may be the reverse of the processing for the forward component. A tracking filter to be used has the arrangement of a filter 8 for synchronization with a reverse-rotational speed. The coefficients of additive and subtractive inputs in the channel crossing of the outputs of the tracking filter 8 may be β's whose signs are opposite to those of the coefficients α's.
FIG. 11 shows experimental data obtained when the rotation-synchronous tracking filter and the channel crossing in the present invention were employed. The rotational speed is shown on the axis of abscissas, while the vibration amplitude is shown on the axis of ordinates. In the figure, "ON" signifies that the operation of the present invention in FIG. 9 was performed. "OFF" signifies that the channel crossing was turned off (corresponding to α=0). It is seen that the vibration amplitude is significantly lowered by the turn-ON, and that it reverts to the original high value due to the turn-OFF.
Thus, according to the method of the present invention, even the resonance amplitude of the bending mode as shown in FIG. 5 is properly damped, and the rotor is permitted to pass the dangerous speed with the small resonance amplitude as indicated by the dotted line.
According to the present invention, the following effects can be achieved:
(a) Any differential circuit need not be added, instead, the channels may be crossed, so that the number of components required is small.
(b) Since a damping force for a forward vibration at a passage through a resonance point can be enhanced, the resonance point can be passed with the unbalance vibration suppressed to a small resonance amplitude.
(c) Even when the balance precision of a rotor is somewhat inferior, the passage through the resonance point is permitted, and hence, balancing operations are simplified. | The present invention reduces the resonance amplitude of the rotational frequency-synchronous unbalance vibration of a rotor supported by an electromagnetic bearing.
To this end, the invention disposes an X-direction control servo circuit and a Y-direction control servo circuit each of which detects the deviation of the rotor from a desired position in the radial direction thereof and controls the rotor so as to be held at the desired position on the basis of the detection signal, and a tracking filter which is synchronous with the rotational frequency. Outputs from the filter are crossed to supply the Y-direction control servo circuit with the X-directional output and to supply the X-direction control servo circuit with the Y-directional output signal. | 5 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to the measurement of time in general, and more particularly to the automatic determination of local time using direct observations of the sun.
More specifically, this invention relates to methods and apparatus for automatically carrying out the determination of lapsed time measurements of the rotation of the surface of a planet in relation to its daily and annual position with its sun.
2. Description of the Prior Art
Devices for determining time by primary reference to sun sightings are, of course, as old as time keeping itself. From the days of the earliest sun dials to the present however, the use of devices and methods for time determination which employ sun observations of all types have required a fair degree of knowledge and agility on the part of the users. These requirements virtually assured that time keeping by sun observations would be largely limited to use by scientists, scholars, and others trained in the setting up, calibrating and interpreting of the means employed.
Simple prior art devices arranged such that a minimum amount of skill would be required for their use invariably suffer from deteriorated accuracy. Exemplary early prior art devices of highly simple configurations are provided in U.S. Pat. No. 1,630,891 to Cooke and in 1,570,349 to Hollingwood. Even given the primitive nature of the devices disclosed therein, it is required that the user manipulate various planes, to insert at least latitude, and perform other approximations prior to use. More recent devices, such as that taught in U.S. Pat. No. 3,940,859 to Troseth, also require a good deal of manual manipulation on the part of the user and, as with most other devices wherein the equation of time is reduced to graphical indicia, suffers from a time reading of only modest accuracy.
SUMMARY OF THE INVENTION
The present invention is primarily directed towards providing a method for the determination of local (alternately solar) time, and an effective apparatus for carrying out the method, wherein a completely automatic timepiece is implemented. Whereas conventional approaches to the determination of solar time require the knowledge of key input parameters, obtainable only during equinoctal periods, the present invention makes use of two solid angles derived wholly from easily obtainable observations and may be unambiguously determined for virtually any location at any time the sun is reasonably high above the horizon. Because of the unique formulation of the time equation implemented, the use of straightforward electronic means is made practical, and the resulting illustrative embodiment teaches the organization of a device which is sufficiently devoid of conceptual limitations as to be useful on any planet having only nominal earth-like characteristics.
Due to the ability of the method employed in the instant invention to be initiated automatically, and to be of broad applicability, the resulting timepiece is ideally suited for use on other planets in addition to earth, and hence may be considered an astronomical timepiece. It is therefore a primary object of this invention to provide improved methods and apparatus for the determination of solar time.
A further object of the present invention is to provide an apparatus for automatically obtaining and displaying highly accurate solar time for any particular location at any annual season.
A further object of the present invention is to provide methods and apparatus for automatically obtaining and displaying accurate solar time wherein no human operator intervention is required for establishing initial operating conditions or for resolving ambiguities in the time determination process.
A further object of the present invention is to provide methods and apparatus for the determination of solar time on planets other than earth where the geophysical characteristics of the planet are less well known, and where no a priori knowledge of the period of rotation of the planet is required.
A further yet object of the present invention is to provide methods for the determination of selected intermediate astronomical (or terrestrial) parameters required for automatic solar time calculation, such as magnetic deviation and true geographical north direction plus axis of rotation data.
A still further object of the present invention is to provide a method for the determination of latitude location, longitude location, geographic north axis direction, and magnetic north deviation from true north -- all from automatic measurements of a minimal number of input data parameters.
BRIEF DESCRIPTION OF THE DRAWINGS
Additional objects and advantages of the invention will become apparent to those skilled in the art as the description proceeds with reference to the accompanying drawings wherein:
FIGS. 1-1A show perspective views of the spatial relationships of key parameters as referenced to a typical planet;
FIG. 2 is a fragmentary elevated view of the astronomical timepiece embodying the inventive concepts of the instant invention;
FIG. 3 is a fragmentary plan view of the astronomical timepiece;
FIG. 4 is a simplified block diagram of an electronic control and display means for the astronomical timepiece; and
FIG. 5 is a perspective view of the spatial relationships between the various quantities sensed and derived.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Spatial Relationships
Referring now to FIG. 1, the spatial relationships between the various sensed and derived parameters are shown on a representative planet having north and south geographic poles N and S. For purposes of illustration, the planet will be assumed to have earth-like properties, that is -- the pole locations define the planet's axis of rotation, the planet has a north magnetic pole somewhere near its north geographic pole, and so forth. However, as will be shown below, the present invention is also operable on planets having less well defined characteristics.
The use of the term "vector" throughout the present specification implies the attribute of direction with unit length. Unless otherwise noted, all vectors originate at the timepiece location (designated point "o") and are directed outward therefrom.
Let a point "o" designate the location of the timepiece 10 for which the apparent local time is to be determined. A first plane, plane A, is positioned such that it contains the three points N, S, and "o". A vector oe defines the local vertical at point "o" and is directed to the center of the planet. A vector oc is directed toward the north geographic pole, and is further aligned such that it is parallel to the planet's axis of rotation, N-S. Both vectors oe and oc lie within plane A. A second plane, plane B, is positioned at point "o" such that it is perpendicular to the vector oc. A vector ob is directed along the line of sight to the sun and, along with vector oc, defines a third plane, plane C. A vector od lying within plane B, is positioned to be perpendicular to plane A and hence defines the geographic east direction. A vector oa defines the intersection of planes B and C, and has the same sense as the vector ob. That is, vector oa is directed outward from the sunward side of plane A.
Note that at this point only three input data parameters were required to establish all other quantities, namely: local vertical; line of sight to the sun; and true geographic north parallel to the planet's axis of rotation. The manner of obtaining these key parameters will be described herein below.
Conventionally an angle θ, defined as that angle between vectors oa and od, is the only angle which can be directly converted to local time in direct proportion to a planet's rotated position with respect to midnight through solution of the equation: ##EQU1##
However, since the angle θ cannot be directly measured except during an equinoctal period, the invention obtains the angle θ indirectly from measurement of a pair of angles α and β. Angle α is defined as that angle between the vectors ob and oc, and angle β is defined as that angle between vectors ob and od. Proof that: ##EQU2## may be found is Appendix I hereto, and can be followed with particular reference to FIG. 1A.
It therefore follows that timepiece 10 can convert the angles α and β directly to a measurement of local time through the solution of the equation: ##EQU3##
Additionally, the timepiece 10 will also provide the latitude location of point "o" by conversion of an angle φ, defined as the angle between vectors oc and oe, by use of the equation:
Latitude = 180° - φ Eqn. 4
Note that the inventor considers the north pole to be located at 0° latitude, equator at 90° latitude, and south pole at 180° latitude.
Additionally, the timepiece 10 will also provide the longitude location of point "o" through the solution of the equation: ##EQU4##
Note that T o = local time at point "o" and that T m = time at an established meridian.
Hardware Operation
Referring now to FIGS. 2 and 3, there is shown a fragmentary elevation view and a plan view, respectively, of an illustrative embodiment of the timepiece according to the present invention. An astronomical timepiece, shown generally at 10, is housed within a platform module 12 and a translucent dome 14. A plurality of levelling leg assemblies 16, having adjustable legs 18 are located at the lower extremities of the platform 12. The platform 12 serves to carry an electronic control and display means (ECDM) for the timepiece 10, and has mounted on it the various sensing and electromechanical means required for the determination of the key parameters from which the desired quantities, particularly local time, will be derived.
A horizontal base member 20 is seated on an upper surface of the platform 12 and is adapted to rotate about a vertical axis 22 when driven by a servo motor 24. The base 20 carries a dome-shaped resistive shell 26 around whose equatorial circumference is positioned three reference points designated ar, br and cr. The shell 26 is substantially hemispherical, the three points ar, br and cr are located in a horizontal plane and are spaced 120° apart. A sun ray sensor assembly 28 is carried by an arcuate sun arm 30 such that the sensor assembly 28 may traverse the substantially 180° length of the sun arm 30 when driven by a servo motor 32. Positioned on the upper surface of the sensor assembly 28, as best seen in FIG. 3, are a plurality of photosensitive cells designated 28x, 28y, and 28z. Positioned at the lower extremity of sensor assembly 28 is a wiping contact, designated pointer 34, which bears frictionally on the outer surface of shell 26. The sun arm 30 is configured to rotate about a horizontal axis 36, via pivot pins 30A and 30B, mounted on the base 20, when driven by a servo motor 38. Functionally, the combination of elements comprising the sun arm 30 and the sensor assembly 28 is rotated in azimuth along with base 20 and shell 26; and the pointer 34 (carried by the sensor assembly 28) may be directed to any angle within the solid angle of approximately 2π steradians by the combined motions of the sensor assembly 28 traversing along sun arm 30, and the rotation of the sun arm 30 about the axis 36.
For ease of reference, the designations and functional names of the servo motors used throughout the timepiece 10 are contained in Table I below.
TABLE 1______________________________________Servo MotorsServo Motor Functional Name______________________________________32 sun sensor traverse38 sun arm rotate24 base member rotate44 ring member rotate50 axis pointer traverse56 axis arm rotate______________________________________
A horizontal ring member 40 is seated on an upper surface of the base member 20, via an intermediate low-frictional surface element 42, and is adapted to rotate about the vertical axis 22 when driven by a servo motor 44. A north axis assembly 46 is carried by an arcuate axis arm 48 such that the axis assembly 46 may traverse the substantially 180° length of the axis arm 48 when driven by a servo motor 50. Positioned on the upper extremity of axis assembly 46 is a wiping contact, designated pointer 52, which bears frictionally on the inner surface of shell 26. The axis arm 48 is configured to rotate about a horizontal axis (in the same plane as the horizontal axis 36) via a pair of pivot pins 58 anchored to elevated portions 54 of ring member 40, when driven by a servo motor 56. Also carried by the axis arm 48 is a wiping contact, designated pointer 52 which is located on the outer extremity of one of said pair of pivot pins opposite servo motor 56 and which bears frictionally on the inner surface of shell 26 in FIG. 3. Functionally, the combination of elements comprising the axis arm 48 and the axis assembly 46 are rotated in azimuth along with the ring 40; and the pointer 52 (carried by the axis assembly 46) may be directed to any angle within the solid angle of approximately 2π steradians by the combined motions of the axis assembly 46 traversing along axis arm 48, and the rotation of axis arm 48 about the horizontal axis defined by the pair of pivot pins previously described. The pointer 58 also rotates in azimuth along with ring 40 and bears on shell 26 in the horizontal plane containing the reference points ar, br and cr.
While the arms 30 and 48 and their respective supporting members 20 and 40 are similar in general configuration, it should be noted that the resistive shell 26 travels in azimuth fixedly with the sun arm 30, and that both the base element 20 and the ring element 40 are independently rotatable in azimuth.
The resistive shell 26 serves as a means for providing the precise locations of pointers 34, 52, and 58, thereby enabling the timepiece 10 to determine the respective vector direction of ob, oc and od as shown in FIG. 1. The vectors are defined as originating at the intersection of axes 22 and 36. Each vector is unambiguously determined by a resistive measurement technique between the appropriate pointers and each of the reference points ar, br and cr. Conceptually, the shell 26 may be considered as an X-Y plane of uniformly distributed surface area resistance which has been shaped into a hemisphere. Both the inner and outer surfaces are so utilized.
For purposes of clarity of exposition, only the major functional elements needed to implement the illustrative mechanism described above have been explicitly set forth. Of course, as is well known to those skilled in the art of precision electromechanical devices, additional elements such as bearings, wiring, hermetic and lubrication seals, slip rings, adjustment means, and so forth, are included in the operational mechanism.
Referring briefly to FIG. 1, and to Table 2 below, a brief overview of the significance of the vectors defined by the positions assumed by pointers 34, 52, and 58, can be seen. In actual operation, the vector ob represents the line of sight to the sun as defined by the position of pointer 34 on the shell 26; the vector oc represents true geographic north (and additionally is parallel to the planet's rotational axis) as defined by the position of pointer 52 on the shell 26; and the vector od represents true geographic east (90° clockwise from and in a plane orthogonal to oc) as defined by the position of pointer 58 on the shell 26.
TABLE 2______________________________________Vector Pointers InitialPointer Function Position Vector______________________________________ Sun At zenith34 Position point of shell 26 ob True Point "ar"52 Geographic on shell 26 oc North True 90° CW of point58 Geographic "ar" on shell 26 od East______________________________________
Referring now to FIG. 4 there is shown, in simplified block diagram form, an electronic control and display means (ECDM) comprising five elements: a display module 60; a microprocessor computing means 62; a power source 64; a control and interface means 66; and a magnetic field sensing means 68. By way of an overview, the following description provides a brief summary of the functions performed by each of these. For the most part they represent fairly conventional and well known entities, and a detailed knowledge of each is not considered essential to an understanding of the inventive concept of the instant invention. The power source 64, illustratively a storage battery of nickle-cadmium, or silver-oxide cells, or the like, provides electrical power to operate the entire timepiece. The display module 60 provides a human-readable digital display capability for the various output data generated by the timepiece. This would display primarily solar time, but also includes sufficient display means for simultaneously reading out other data such as earth time, and latitude/longitude. The microprocessor and computing means 62 is the primary computational entity for the timepiece, and is comprised of a conventional microprocessor supported by suitable ROMS (read-only memories), RAMS (random-access memories) and programming. The computing means 62 accepts the input data parameters in compatible form from the various electromechanical assemblies, performs the calculations indicated by the equations 1-8 described herein, and provides the desired output data to the display module 60. The control and interface means 66 serves to interface the various elements of the timepiece, especially those of the ECDM, and also performs the remainder of the electronic housekeeping tasks required in the timepiece. Illustratively, the interfacing means 66 accepts the outputs from computing means 62 and converts them to suitable power levels and in proper formats for operating the display module 60, the plurality of servo motors, the leg assemblies 16, and so forth. The magnetic field sensing means 68, illustratively a self-contained instrument comprising an array of flux gate sensors or the like, provides magnetic north data as required to initially position the base member 20, and to implement the feature described in connection with equation 8 hereinbelow.
Referring again to FIGS. 2 and 3, the techniques for acquiring the three input data parameters required by the timepiece 10 are described. By way of providing a set of initial conditions, reference is made to the data of Table 2. There it is seen that sun ray sensor assembly 28 is positioned such that the pointer 34 (sun position) is at the zenith point on shell 26; north axis assembly 46 is positioned such that pointer 52 (true geographic north) is at the reference point ar on shell 26; and that ring member 40 is positioned such that the pointer 58 (true geographic east) is at the point ar plus 90° clockwise as viewed from above (the zenith point) on shell 26.
The local vertical direction is first established. This may be done by a variety of means, all well known to those skilled in the art, including the use of well-known bubble sensors. For example, bubble level devices disposed at three of the four corners of platform module 12 may be used to provide control signals via electronic means to actuate the length adjusting drive means (all not shown) of adjustable legs 18 of leg assemblies 16. Alternately, pendulous mass sensors, or the like, mounted within the timepiece 10 may be used to provide the control signals. Of course, simpler manually-operated means may also be employed. Further details of a typical levelling mechanism, while not essential to an understanding of the instant invention, may be had by reference to U.S. Pat. No. 2,941,082 to Carbonara et al. On completion of this levelling step, the vertical axis 22 becomes the primary vertical reference and the horizontal axis 36 becomes the primary horizontal reference. Note that axis 22 of FIG. 2 is, in actual operation, identical to the vector oe as shown in FIGS. 1 and 5. Base member 20 and ring member 40 are also horizontal and are configured to sweep out precision horizontal planes upon rotation in azimuth.
Determination of the vector ob is made via sun ray sensor assembly 28 as follows. Automatically upon command from the ECDM, or upon initiation of a time determination sequence by whatever means, sensor assembly 28 is enabled to be positioned in response to the light-sensitive cells 28x-28z as shown in FIG. 3. From the initial position of sensor assembly 28, at least one of the triad-configured cells 28z-28z will be illuminated by the sun (assuming of course that the sun is above the local horizon) thereby providing an initial direction for a two-axis electronic servo system (not shown) which drives servo motors 32 and 38. Advantageously, the servo motors 32 and 38 as well as all other servo motors described herein are of the discrete stop type having a minimum step size consistent with the desired driven element granular accuracy, and minimizing the quiescent drive power requirements. Following motion in the appropriate initial direction, subsequent accurate positioning of sensor assembly 28 is achieved by the combined motions of its traversing via servo motor 32 in response to the relative outputs of cells 28x and 28z, and rotating of sun arm 30 via servo motor 38 in response to the relative outputs of cells 28y and 28z. Note that the most sensitive axes of cells 28x-28x are angularly displaced at some acute angle so that the incident sun rays must be made to bisect their included angles to equalize the outputs provided by any combination of the two cells. Two axis electromechanical servo positioning systems responsive to incident sun rays are well known to those skilled in the art. While the details of electromechanical servos are not essential to a clear exposition of the inventive concepts taught herein, additional details of such devices may be had by reference to U.S. Pat. No. 3,480,779 to Hand, Jr., and to U.S. Pat. No. 3,996,460 to Smith.
Upon stabilization of the sensor assembly 28 tracking, the vector ob is defined for use thereafter by the ECDM using the position of pointer 34 on shell 26 relative to the three reference points ar, br, and cr.
The determination of vector oc, the true north (plus axis) direction is accomplished in three steps as follows. Firstly, rotation of base member 20 is enabled via the ECDM, and a magnetic field sensing means 68 is used to provide control signals to drive the servo motor 24 such that reference point ar on shell 26 is pointed to the local (terrestrial or otherwise) magnetic north. Secondly, the north axis assembly 46 is driven to an intermediate position in response to two successive readings taken of the apparent arc of the sun. The ECDM records a first vector point reading ob x , as shown in FIG. 5, and takes no further action until the sun has displaced itself by some predetermined angle. illustratively, this predetermined angle may be on the order of a few tens degrees -- say 15°-30°, and of course is under the control of a program being executed in the ECDM. The ECDM then records a second vector point reading ob y . On obtaining the readings of ob x and ob y , servo motor 44 is energized to rotate ring member 40 from its initial position exactly 350° in the counterclockwise direction, and then is made to pause. The ECDM program monitors each discrete step of servo motor 44 and calculates the two positions of pointer 58 where angle d'ob x equals angle d'ob y . Of the two positions, the positions closest to magnetic north point (ar) is chosen and servo motor 44 once again is energized so as to direct pointer 58 to that particular location. Servo motor 56 is then energized under control of the ECDM so as to rotate axis arm 48 counterclockwise from its initial position. Axis arm 48 continues to rotate about the axis containing pointer 58 until angle cob x equals angle cob y . Having thus positioned the ring member 40 and the axis arm 48 as above, the third and final step for the determination of vector oc may be completed upon one further displacement measurement of the sun. This is done by taking a third vector point reading ob z , after some predetermined sun angle displacement as before. The servo motor 50 is then energized so as to traverse north axis assembly 46 along the axis arm 48 in a first direction (or a second direction upon reaching a mechanical limit stop) so as to direct the pointer 52 until angle cob x equals angle cob z . The ECDM now signals servo motors 56 and 50 to become free-wheeling while driving servo motor 44 until pointer 58 is both 90° from pointer 52, and is east of referene point ar. Pointer 52 applies sufficient pressure to shell 26 to enable the rotation of pointer 58 without moving pointer 52 when servo motors 56 and 50 are free-wheeling. Pointer 52 now points to true geographic north with its axis parallel to the planet's axis and thus the vectors oc and od are fully defined. (Pointer 52 would be pointing to true geographic south if the final rotated angle from initial rest position of axis arm 48 was greater than 90°.) At this point the acquisition of the required three input data parameters is complete.
Summarizing the subsequent operation of timepiece 10 is in order at this time. The sun ray sensor assembly 28 will continue tracking of the apparent arc of the sun about the true north axis for as long as the sun is above the visual horizon or until mechanical limits are met. The vectors oc, od, and oe remain, of course, constant as long as the timepiece 10 remains at the same location. Hence there is provided a continuous determination of the angles α and β which lie between the vectors ob and oc, and between the vectors ob and od respectively, and therefoore a continuous capability within the ECDM for calculating and displaying solar time according to equation 3 above.
ALTERNATE EMBODIMENTS AND USES
When the timepiece 10 according to the instant invention is functioning on a planet other than earth, the time required for the planet to revolve about its rotational axis will most likely take more or less than 24 earth hours to complete. To determine exactly how many earth hours it takes for a planet to revolve around its axis, the ECDM can be programmed to take a planet solar time reading T o1 and store it. At the same time, the ECDM will take a time reading from an on-board earth clock, designated time T e , and store it as time T e1 . After the planet's sun has completed a predetermined (assume 15°) arc in the planet's sky, the ECDM will take another pair of corresponding readings designated T o2 and T e2 . The length of the planet's day and the planet's hour can be measured in earth hours by solving the following equations. ##EQU5##
In addition to the calculation of solar time by means of the timepiece 10 according to the instant invention, both latitude and longitude locations of the timepiece may also be determined. Considering longitude -- solution of the equations 6 and 6A will enable the establishment of a planet clock wherein one complete planet day may be divided into a number of arbitrary time increments. Selecting twenty-four increments, consonant with earth clock increments, the planet clock may be proportionately calibrated and for purposes of illustration will be designated as planet time T m . T m will now become the reference meridian time for the entire planet. If the timepiece 10 were to be relocated to another longitude location upon the surface of the planet, a time clock T o would be initiated. The longitude location of the second site with respect to the original site can be determined through the solution of equations 5 and 5A.
Considering latitude -- the latitude location of the instant invention at any location on a planet's surface can be determined by measuring the final rotated position of the axis arm 48 as shown in FIG. 2. The final rotated position of axis arm 48 is defined as Φ' where: ##EQU6## Note that (φ'-90°) equal φ as shown in FIG. 1 and as before the present invention recognizes latitude angle to be 0° at the north pole, 90° at the equator, and 180° at the south pole.
Additionally, utilizing the coordinates system available from the invention, a gyro compass heading could be initiated or could be corrected with reference to magnetic north. The reverse could also be true to establish the position of pointer 52 as shown in FIG. 2. If such cross-reference is available, the long time lapse required to establish true north at each new site location would not be necessary. If the timepiece of the instant invention were supported with the aid of a gyro compass, the timepiece could monitor time continuously during travel status. If the timepiece were mounted in an airplane on earth, and the unit was set for continuous monitoring of time, time readings would slow down and even run backwards as the westbound airplane would approach and exceed the surface rotation speed of the earth. Time readings would go ever faster in an ever faster eastbound plane. Time reading increments would remain constant and normal in a north or south bound plane following a longitudinal line course.
Magnetic north deviation is monitored within the timepiece 10 by measuring the angle displacement of pointer 58 and reference point ar on shell 26, as shown in FIG. 3. The angle displacement of pointer 58 in reference to point ar is angle ∠doar as shown in FIG. 5. Magnetic north deviation may therefore as calculated, and stored if required in the ECDM, utilizing the following calculation:
Magnetic deviation = 90° - ∠doar Eqn. 8
Note that a positive angle means magnetic north lies east of true north and a negative resultant angle means magnetic north lies west or true north.
Finally, it is noted that the electromechanical implementation set forth in the illustrative embodiment should not be considered as a limitation on either the methods taught herein, or on other possible analogous mechanisms. Basically, the illustrative embodiment discloses the use of an independent pair of servo driven assemblies each of which comprises a curved arm of 180° length which is rotatable about a horizontal axis, and a traverse assembly carried thereby. Together, these two subassemblies merely implement an easily controllable means for positioning a pointer within a 2 π steradian angle, as "read out" on a hemispherical potentiometer in the form of a resistive shell. Obviously, equivalent non-servo means may be used for these purposes and may be considered entirely analogous. Considering, for example, that pointer 52 (north axis; vector oc) has for its primary function the providing of solid angle data to the ECDM, a fully equivalent means for doing this are well known and available. Illustratively, the ECDM control signals which drive servo motor 56 to rotate axis arm 48 may be converted to digital form and stored. Similarly, the control signals which drive servo motor 50 to move the axis assembly 46 may be stored in digital form. Straightforward digital manipulation would then yield the vector oc in digital form. Likewise the angles α and β could be digitally derived without servo driven, physically articulated mechanisms.
Although the present invention has been described in terms of selected illustrative embodiments, and alternate embodiments, the invention shohuld not be deemed limited thereto since other embodiments and modifications will readily occur to one skilled in the art. It is therefore to be understood that the appended claims are intended to cover all of such modifications as fall within the true spirit and scope of the invention.
Appendix I -- Derivation of Equation 2
A proof that angle θ may be derived from the angles α and is set forth below, with particular reference to FIG. 1A. ##EQU7## | A method and apparatus for determining local solar time for virtually any location on any planet having a radiating sun, wherein the method requires minimal a prior knowledge of the planet's major characteristics and the apparatus is organized so as to permit completely automatic determination of the key parameters from which the time calculation is derived. Advantageously, the time determination is accomplished using a formulation of the time equation which depends on two key solid angles initially obtainable any time the planet's sun is reasonably high above the horizon. Additionally, methods are outlined which permit the apparatus to provide basic navigational data, such as latitude and longitude locations (for other than extreme polar positions) of the timepiece. | 6 |
FIELD OF THE INVENTION
[0001] This invention relates to an automatic braking light or stop light for pedal cycles and the like and is particularly applicable for vehicles with no electric system.
BACKGROUND TO THE INVENTION
[0002] Many pedal cyclists suffer injuries or death in traffic accidents every year. One reason for this is that acceleration and deceleration of a cyclist is erratic when compared to motor powered vehicles as it is influenced by factors such as incline of the road, the gear being used and the level of fatigue of the cyclist. As it is very difficult to predict acceleration and deceleration of a cyclist, other road users try to pass them by with a wider berth than they would typically give other road users. However, where a cyclist decelerates suddenly without warning and is in the path of another road user, it is sometimes too late to react properly by the time the other road user has realized the cyclist is/has decelerated.
STATEMENT OF INVENTION
[0003] According to an aspect of the present invention, there is provided an automatic braking light for a vehicle, the automatic braking light including an inertia driven switch circuit and a warning light, wherein the inertia driven switch circuit includes a holder for the power source arranged to swing overhead a pivot/axle from a stop where it is at rest forward to a resilient spring, the resilient spring being arranged to absorb the deceleration force and simultaneously connect the power source to the warning light during deceleration of the vehicle and thereby activate the warning light.
[0004] The present invention seeks to provide an automatic braking light that can be fixed to pedal cycles and other vehicles and is inertia-activated on deceleration. In a preferred embodiment, the braking light includes a case in which a battery in a holder swings overhead a pivot/axle from a stop where it is at rest forward to a resilient spring means which absorbs the deceleration force and simultaneously closes an electric circuit to a display of light emitting diodes to thereby provide a warning to other road users of the deceleration.
[0005] The holder is preferably arranged to swing in an arc between predetermined angles of rest and arrest, said angles being maintained by rigid attachment of the unit to the vehicle.
[0006] The resilient spring preferably comprises a leaf spring, the angle and tension of the leaf spring being selected so as to absorb the forward momentum of the holder on deceleration, and to deflect the holder to the rest position upon cessation of decelerating forces.
[0007] The resilient spring is preferably electrically conductive and is connected to the warning light which is in turn connectable to a pole of the power source, the other pole of the power source being connectable to an electrical contact on the exterior of the holder, the electrical contact being positioned to contact the resilient spring during deceleration and thereby close the switch circuit.
[0008] The warning light preferably includes a plurality of light emitting diodes. The light emitting diodes may be arranged in a cross shape.
[0009] The braking light may further comprise an override switch, the override switch being arranged to activate at least a number of the light emitting diodes light for continuous operation.
[0010] The braking light may further comprise a further light and a continuous operation switch, the further light being activatable by the continuous operation switch and being independent and visually distinguishable from the warning light.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] An embodiment of the present invention will now be described in detail, by way of example only, with reference to the accompanying drawings in which:
[0012] FIG. 1 shows, in perspective, a braking light according to an embodiment of the present invention fitted to a cycle frame;
[0013] FIG. 2 is a sectional view of the braking light of FIG. 1 in an “off” position;
[0014] FIG. 3 is a sectional view of the braking light of FIG. 1 in an “on” position;
[0015] FIG. 4 is a sectional view along the line a-a of FIG. 3 ;
[0016] FIG. 5 is a plan view of a preferred configuration of a nine LED display for use in the braking light of FIG. 1 ; and,
[0017] FIG. 6 is a schematic diagram of the circuit layout for the nine LED display of FIG. 5 .
DETAILED DESCRIPTION
[0018] FIG. 1 shows, in perspective, a braking light according to an embodiment of the present invention fitted to a cycle frame. The braking light unit includes a compact case 10 secured to the cycle frame 2 under the saddle 12 by a rigid attachment bracket 11 which maintains the angle of operation of the components of the unit Access for battery replacement is via a lid 14 on top of the case 10 . A nine LED display 15 projects to the rear.
[0019] FIG. 2 is a sectional view of the braking light of FIG. 1 in an “off” position and FIG. 3 is a sectional view of the braking light of FIG. 1 in an “on” position. The unit 1 includes a battery holder 16 that is arranged to pivot over an offset axle 17 . In the “off” position, the battery holder 16 rests on a stop 18 at an angle of approximately 42° above horizontal. The nine LED display 15 is mounted on a printed circuit board 20 fitted towards the rear of the case 10 , under a translucent cover 21 .
[0020] The arc of forward movement of the holder 16 to an “on” position, as shown in FIG. 3 , is confined to approximately 50°. The holder is arrested by an electrically conducting resilient spring 19 (preferably a leaf spring) and a forward stop/front wall of the case which is fixed at an angle of approximately 62° above horizontal.
[0021] FIG. 4 is a sectional view along the line a-a of FIG. 3 . The battery holder 16 pivots over the axle 17 held in bearings 22 in the side walls of the case. In this example the inertia mass is provided by a PP3 9volt battery inserted into positive and negative sockets 23 inside the holder and clipped in place.
[0022] The positive socket is connected to a curved metal shoe 24 on the upper outside of the holder 16 , which makes contact with the resilient spring 19 when the holder 16 is thrown forward on deceleration. The resilient spring 19 is connected to the positive feed of the LED display 15 via an integral circuit and resistor (not shown).
[0023] A flexible wire 25 connects the negative pole of the battery holder 16 to the negative feed of the LED display 15 . Therefore, when the metal shoe 24 of the battery holder 16 contacts with the resilient spring 19 , thereby closing the circuit and illuminating the LED display 15 .
[0024] Further applications of this braking light are envisaged to all forms of wheeled conveyances such as tricycles, pedal rickshaws, wheelchairs, powered scooters and railway rolling stock. The system can be scaled down or enlarged to suit these situations. The nine LED arrangement also lends itself to a triangular configuration, although other numbers, colors or arrangements of LEDs (or other lighting elements) can be envisaged and substituted for those described herein. In addition or alternatively, other warning means could be used, such as a horn, a bell, a mechanical indicator or an electronic display.
[0025] The lighting time of the LED can be prolonged by the addition of a capacitor or similar element or circuit.
[0026] The braking light can be modified to incorporate a continuous three-LED display tail light with manual switch for night operation. The three-LED display may be of a different pattern and/or color to the warning light and mounted in the same housing. Alternatively, three LEDs could be illuminated with the remainder being activated when the braking circuit is closed.
[0027] It will be appreciated that other inertia change detection systems could be substituted for the battery mounted in a battery holder pivoting over an axle. For example, a mercury based switch or the like could be used. In addition, an incline sensor (again such as a mercury based switch) could be used to avoid the brake light activating when cycling down an incline, over potholes and the like. It will also be appreciated that other power sources could be substituted for batteries, for example a rechargeable power source (charged by an external source or by a dynamo attached to the cycle).
[0028] It will also be appreciated that the braking light could be attached to the vehicle at other points using an appropriate mount | An inertia-activated braking light ( 1 ) for attachment to pedal cycles and the like. A display of LEDs ( 15 ) is automatically illuminated on deceleration. This is achieved by an inertia mass closing a circuit on deceleration to provide electrical power to illuminate the light emitting diodes. | 1 |
FIELD OF THE INVENTION
The present invention relates to integrated circuit packaging and manufacturing thereof, and more particularly, to integrated circuit packaging for enhanced dissipation of thermal energy.
BACKGROUND OF THE INVENTION
A semiconductor device generates a great deal of heat during normal operation. As the speed of semiconductors has increased, so too has the amount of heat generated by them. It is desirable to dissipate this heat from an integrated circuit package in an efficient manner.
A heat sink is one type of device used to help dissipate heat from some integrated circuit packages. Various shapes and sizes of heat sink devices have been incorporated onto, into or around integrated circuit packages for improving heat dissipation from the particular integrated circuit package. For example, U.S. Pat. No. 5,596,231 to Combs, entitled “High Power Dissipation Plastic Encapsulated Package For Integrated Circuit Die,” discloses a selectively coated heat sink attached directly on to the integrated circuit die and to a lead frame for external electrical connections.
SUMMARY OF THE INVENTION
In one aspect, the invention features an integrated circuit package with a semiconductor die electrically connected to a substrate, a heat sink having a portion thereof exposed to the surroundings of the package, a thermally conductive element thermally coupled with and interposed between both the semiconductor die and the heat sink, wherein the thermally conductive element does not directly contact the semiconductor die, and an encapsulant material encapsulating the thermally conductive element and the heat sink such that a portion of the heat sink is exposed to the surroundings of the package.
In another aspect, the invention features an integrated circuit package with a semiconductor die electrically connected to a substrate, a heat sink having a portion thereof exposed to the surroundings of the package, means for thermally coupling the semiconductor die with the heat sink to dissipate heat from the semiconductor die to the surroundings of the package, wherein the means for thermally coupling is interposed between the semiconductor die and the heat sink but does not directly contact the semiconductor die, and means for encapsulating the thermally conductive element and the heat sink such that a portion of the heat sink is exposed to the surroundings of the package.
In yet another aspect, the invention features an integrated circuit package with a substrate having an upper face with an electrically conductive trace formed thereon and a lower face with a plurality of solder balls electrically connected thereto, wherein the trace and at least one of the plurality of solder balls are electrically connected, a semiconductor die mounted on the upper face of the substrate, wherein the semiconductor die is electrically connected to the trace, a heat sink having a top portion and a plurality of side portions, a thermally conductive element thermally coupled to but not in direct contact with the semiconductor die, wherein the thermally conductive element is substantially shaped as a right rectangular solid, is interposed between said semiconductor die and said heat sink, and is attached to said heat sink, and an encapsulant material formed to encapsulate the upper face of the substrate, the semiconductor die, the thermally conductive element and substantially all of the heat sink except the top portion and the side portions of the heat sink.
In a further aspect, the invention features an integrated circuit package with a substrate having means for electrically interconnecting a semiconductor die and means for exchanging electrical signals with an outside device, a semiconductor die attached and electrically connected to the substrate by attachment means, a heat sink having means for dissipating thermal energy to the surroundings of the package, means for thermally coupling the semiconductor die to the heat sink to dissipate heat from said semiconductor die to the surroundings of said package, wherein said means for thermally coupling is interposed between said semiconductor die and said heat sink but does not directly contact the semiconductor die, and means for encapsulating said semiconductor die, said thermally conductive element and said heat sink such that said portion of said heat sink is exposed to the surroundings of said package but is substantially encapsulated.
In another aspect, the invention features a method of manufacturing an integrated circuit package including installing a carrier onto an upper surface of a substrate, wherein the carrier defines a cavity, attaching a semiconductor die to the upper surface of the substrate within the cavity of the carrier, aligning an assembly over the semiconductor die, wherein the assembly comprises a heat sink and a thermally conductive element, resting the assembly on the carrier such that the thermally conductive element does not directly contact the semiconductor die, and encapsulating the cavity to form a prepackage such that a portion of the heat sink is exposed to the surroundings of the package.
In yet another aspect, the invention features a method of manufacturing an integrated circuit package including installing a carrier onto a substrate, attaching a semiconductor die to the substrate, aligning an assembly over the semiconductor die, wherein the assembly has a heat sink and a thermally conductive element, resting the assembly on the carrier such that the thermally conductive element does not directly contact the semiconductor die, and encapsulating the thermally conductive element and the heat sink such that a portion of the heat sink is exposed to the surroundings of the package.
BRIEF DESCRIPTION OF THE DRAWINGS
The foregoing features and other aspects of the invention are explained in the following description taken in connection with the accompanying drawings, wherein:
FIG. 1 is a simplified cross-sectional view of an integrated circuit package according to one embodiment of the present invention;
FIG. 2 is a simplified cross-sectional view of a subassembly of the integrated circuit package shown in FIG. 1, prior to encapsulation and singulation assembly steps;
FIG. 3 is a simplified cross-sectional view of an integrated circuit package according to another embodiment of the invention, which has a direct chip attachment;
FIG. 4A is a plan view of the subassembly of FIG. 2 having one type of heat sink assembly used in the integrated circuit package shown in FIG. 1;
FIG. 4B is a plan view of a subassembly of an integrated circuit package having a second type of heat sink capable of being used in the integrated circuit package shown in FIG. 1;
FIG. 5 is a plan view of the heat sink shown in the subassembly of FIG. 4A;
FIG. 6 is a plan view of a heat sink assembly as shown in FIG. 4A, which becomes the heat sink shown in FIG. 5 once assembled into an integrated circuit package such as the embodiment shown in FIG. 1;
FIG. 7 is a plan view of a third type of heat sink capable of being used in the integrated circuit package shown in FIG. 1;
FIG. 8 is a plan view of a fourth type of heat sink capable of being used in the integrated circuit package shown in FIG. 1;
FIG. 9A is a plan view of a matrix frame containing a “3×3” matrix of heat sinks of the type shown in FIG. 5;
FIG. 9B is a plan view of another matrix frame containing a “2×3” matrix of heat sinks of the type shown in FIG. 4B;
FIG. 10 is a simplified cross-sectional view along line A—A of the heat sink shown in FIG. 5, and a thermally conductive element of one embodiment; and
FIG. 11 shows a flowchart of major steps performed in assembly of one embodiment of an integrated circuit package.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
Various embodiments of the integrated circuit package of the present invention will now be described with reference to the drawings.
FIG. 1 shows certain components of an integrated circuit package according to one embodiment of the present invention displayed in their respective positions relative to one another. The integrated circuit package depicted in FIG. 1 generally includes a substrate 100 , a heat sink 110 , an adapter assembly 120 , a semiconductor die 130 and an encapsulant 140 . Each of the foregoing will now be described in greater detail along with the manufacturing steps (shown in FIG. 11) associated with them.
A substrate 100 of either a rigid material (e.g., BT, FR4, or ceramic) or a flexible material (e.g., polyimide) has circuit traces 102 onto which a semiconductor die 130 can be interconnected using, for example, wire bonding techniques, direct chip attachment, or tape automated bonding. FIG. 1 shows a semiconductor die 130 connected to the traces 102 of the substrate 100 via a gold thermo-sonic wire bonding technique. In such an embodiment, gold wires 104 interconnect the semiconductor die 130 to the traces of the substrate 100 . In another embodiment, shown in FIG. 3, the semiconductor die 130 is connected to the traces 102 via a direct chip attachment technique including solder balls 105 . The substrate 100 may be produced in strip form to accommodate standard semiconductor manufacturing equipment and process flows, and may also be configured in a matrix format to accommodate high-density packaging.
In one embodiment, the traces 102 are embedded photolithographically into the substrate 100 , and are electrically conductive to provide a circuit connection between the semiconductor die 130 and the substrate 100 . Such traces 102 also provide an interconnection between input and output terminals of the semiconductor die 130 and external terminals provided on the package. In particular, the substrate 100 of the embodiment shown in FIG. 1 has a two-layer circuit trace 102 made of copper. A multilayer substrate may also be used in accordance with an embodiment. The substrate 100 shown in FIG. 1 has several vias drilled into it to connect the top and bottom portions of each circuit trace 102 . Such vias are plated with copper to electrically connect the top and bottom portions of each trace 102 . The substrate 100 shown in FIG. 1 also has a solder mask 107 on the top and bottom surfaces. The solder mask 107 of one embodiment electrically insulates the substrate and reduces wetting (i.e., reduces wanted flow of solder into the substrate 100 .)
As shown in FIG. 1, the external terminals of the package of one embodiment of the present invention include an array of solder balls 106 . In such an embodiment, the solder balls 106 function as leads capable of providing power, signal inputs and signal outputs to the semiconductor die 130 . Those solder balls are attached to corresponding traces 102 using a reflow soldering process. The solder balls 106 can be made of a variety of materials including lead (Pb) free solder. Such a configuration may be referred to as a type of ball grid array. Absent the solder balls 106 , such a configuration may be referred to as a type of LAN grid array.
As shown in FIGS. 1 and 2, the semiconductor die 130 may be mounted or attached to the substrate 100 (step 1115 ) with an adhesive material 115 , such as epoxy. However, as shown in FIG. 3, a solder reflow process or other suitable direct chip attachment technique may also be used as an alternative way to attach the semiconductor die 130 to the substrate 100 (step 1115 ).
In the embodiment shown in FIG. 1, the heat sink 110 is aligned with and positioned above the top surface of the semiconductor die 130 , but not in direct contact with any portion of the semiconductor die 130 . The heat sink 110 is preferably made of a thermally conductive material such as copper or copper alloy.
One embodiment of an assembly process for manufacturing an integrated circuit package of the present invention uses a carrier 200 as shown in FIGS. 2, 4 A and 4 B. FIG. 2 shows, in cross-sectional view, a carrier 200 installed onto the substrate 100 . The carrier 200 can be mounted on the substrate 100 by mechanical fastening, adhesive joining or other suitable technique (step 1110 ). The carrier 200 may have one or more recesses 202 sized to accept support structure 114 of a heat sink assembly (step 1125 ). In general, the carrier 200 is configured to accept either an individual heat sink assembly (as shown in FIGS. 4 A and 4 B), or a matrix heat sink assembly 310 containing a number of ad heat sinks 110 (as shown in FIGS. 9A and 9B) in order to align and install heat sinks 110 of either single semiconductor packages, or arrays of packages manufactured in a matrix configuration. The support structure 114 helps to properly align the heat sink 110 during Ian assembly (step 1120 ) and, accordingly, may be removed (as discussed below) in whole or in part prior to completion of an integrated circuit package. In one preferred embodiment, however, some portions of the support structure 114 remain in the final integrated circuit package and are exposed to the ambient environment. For example, in the embodiment depicted in FIG. 1, portions of the support structure 114 serve as heat dissipation surfaces.
Further details of the heat sink 110 of a subassembly shown in FIG. 4B include extending fingers 116 - 1 , 116 - 2 , 116 - 3 and 116 - 4 of the support structure 114 . As shown in plan view by FIG. 4B, the fingers 116 - 1 , 116 - 2 , 116 - 3 and 116 - 4 may be sized and shaped to engage matching wells or recesses 202 - 1 , 202 - 2 , 202 - 3 and 202 - 4 in the supporting walls of the carrier 200 (step 1125 ). Such fingers 116 - 1 , 116 - 2 , 116 - 3 and 116 - 4 in whole or in part support the heat sink 110 prior to encapsulation (step 1130 ) and align the heat sink 110 above the semiconductor die 130 .
A number of types of heat sinks 110 may be used. FIGS. 4B, 5 , 7 and 8 each show a different geometry for a heat sink 110 . The heat sink 110 may be sized and configured for use in a specific package arrangement. For example, the heat sink 110 may be sized for incorporation into a package having only a single semiconductor die 130 (see FIG. 1 ). Alternatively, several heat sinks 110 may be arranged in a matrix configuration 300 to accommodate the assembly of several packages at once. Such a matrix configuration 300 is selected to allow each heat sink 110 of the matrix to be aligned with the corresponding semiconductor die 130 and an underlying matrix package substrate 100 . Although a 2×3 and a 3×3 matrix of heat sinks 110 within each matrix heat sink assembly 310 are shown in FIGS. 9A and 9B, a number of matrix combinations and configurations are acceptable. FIG. 9A shows a 3×3 matrix of heat sinks 110 , wherein each heat sink 110 has a geometry similar to that of an embodiment shown in FIGS. 4A, 5 and 6 . FIG. 9B shows a 2×3 matrix of heat sinks 110 , wherein each heat sink 110 has a geometry similar to that of an embodiment shown in FIG. 4 B.
In one embodiment, the heat sink 110 has a raised portion 112 protruding above a primary plane of the heat sink 110 . As shown in FIG. 10, an exposed surface of the raised portion 112 may be plated with nickel 116 , and functions as a heat dissipation interface with the ambient environment. The nickel plating 116 protects the heat sink 110 during environmental testing by resisting oxidation of certain heat sink materials, such as copper. The raised portion 112 can be formed by removing the surrounding portion of the upper surface of the heat sink 110 , for example, by etching. In a preferred embodiment, the heat sink 110 is also oxide coated to enhance the adhesion between the encapsulant material 140 and the heat sink 110 . The oxide coating may be achieved or applied by chemical reaction.
The adaptor assembly 120 shown in FIGS. 1 and 2 provides a thermal path between the semiconductor die 130 and the heat sink 110 . Such an adaptor assembly 120 includes an adaptor element 122 made of a thermally conductive material (e.g., alumina (Al 2 O 3 ), aluminum nitride, beryllium oxide (BeO), ceramic material, copper, diamond compound, or metal) appropriate for heat transfer between the semiconductor die 130 and the heat sink 110 . In one embodiment, the adaptor element 122 is shaped as a right rectangular solid, such that its upper and lower faces have dimensions similar to the upper face of the semiconductor die 130 .
One dimension of the adaptor element 122 may be selected to match the area of the upper surface of the semiconductor die 130 . The thickness of the adaptor element 122 may also be selected to accommodate size variations of the semiconductor die 130 and the heat sink 110 . By reducing the distance between the semiconductor die 130 and the externally exposed heat sink 110 , the adaptor assembly 120 reduces the thermal resistance of the die-to-sink interface.
In a preferred embodiment, the distance from the upper surface of the semiconductor die 130 to the adaptor element 122 is minimized to reduce the thermal resistance between the semiconductor die 130 and the heat sink 110 . However, to avoid imparting stress to the semiconductor die 130 , the adaptor element 122 does not directly contact the semiconductor 130 surface. In a preferred embodiment, the distance between the adaptor element 122 and the semiconductor 130 surface is about five (5) mils or less.
An adhesive layer 119 , having both high thermal conductivity and deformability to minimize stress, such as an elastomer, may be used to join the adaptor element 122 to the heat sink 110 . In a preferred embodiment, such an adhesive layer 119 is electrically and thermally conductive.
The adaptor assembly 120 may also include a polymeric thermal interface 124 between the semiconductor die 130 and the adaptor element 122 to further minimize the thermal resistance of the die-to-sink interface. In a preferred embodiment, the coefficient of polymeric thermal expansion (CTE) of the thermal interface 124 is similar to that of silicon to minimize stress on the semiconductor die 130 . In one embodiment, a thermal interface 124 portion of the adaptor assembly 120 may be attached to the heat sink 110 to reduce the distance from the surface of the semiconductor die 130 to the heat sink 110 .
As shown in FIG. 1, the semiconductor die 130 , adaptor assembly 120 and a portion of the heat sink 110 are encapsulated to form an integrated circuit package according to one embodiment of the present invention. The encapsulant 140 may be an epoxy based material applied by, for example, either a liquid molding encapsulation process or a transfer molding technique. In one assembly method embodiment of the invention, the encapsulation step 1130 occurs after the carrier 200 is attached to the substrate 100 (step 1110 ), and the heat sink 110 is installed in the carrier 200 (step 1125 ). During such an encapsulation step 1130 , the cavity 204 of the carrier 200 is filled with encapsulant 140 . Solder balls 106 are then attached to the traces 102 of the substrate 100 using a reflow soldering process. After such encapsulation and ball attachment assembly steps, the integrated circuit packages are removed from the strip and singulated into individual units using a saw singulation or punching technique (step 1135 ). Upon completion of these assembly steps, the top portion 112 and some portions of the support structure 114 of the heat sink 110 remain exposed to allow heat transfer and dissipation to the ambient environment of the integrated circuit package (see FIG. 1 ).
Although specific embodiments of the present invention have been shown and described, it is to be understood that there are other embodiments which are equivalent to the described embodiments. Accordingly the invention is not to be limited by the specific illustrated embodiments, but only by the scope of the appended claims. | In one aspect, the present invention relates to an integrated circuit package includes a scmiconductor die electrically connected to a substrate, a heat sink having a top and a side portion, the heat sink further including an extending finger when viewed from a top of the package, the extending finger including the side portion of the heat sink, a thermally conductive element thermally coupled with an interposed between both the semiconductor die and the heat sink, wherein the thermally conductive element does not directly contact the semiconductor die, and an encapsulant material encapsulating the thermally conductive element and the heat sink such that the top portion and the side portion of the heat sink are exposed to the surroundings of the package. | 7 |
TECHNICAL FIELD
This disclosure relates to the field of hybrid transmissions for motor vehicles. More particularly, the disclosure pertains to the structure and support of components in a hybrid electric transmission.
BACKGROUND
Many vehicles are used over a wide range of vehicle speeds, including both forward and reverse movement. Most types of internal combustion engines, however, are capable of operating efficiently only within a narrow range of speeds. Consequently, transmissions capable of efficiently transmitting power at a variety of speed ratios are frequently employed. When the vehicle is at low speed, the transmission is usually operated at a high speed ratio such that it multiplies the engine torque for improved acceleration. At high vehicle speed, operating the transmission at a low speed ratio permits an engine speed associated with quiet, fuel efficient cruising.
In an effort to reduce fuel consumption, some transmissions are designed to utilize substantial amounts of energy storage in addition to liquid fuel burned in an internal combustion engine. Most commonly, the energy storage takes the form of electric batteries. The transmission diverts power to the batteries and utilizes power from the batteries using one or more reversible electric machines, such as synchronous motors or induction motors. A vehicle that uses traditional liquid fuel and also includes electrical storage is called a hybrid electric vehicle (HEV). When the vehicle includes provisions to charge the electric batteries from an external source, the vehicle is called a plug-in hybrid electric vehicle (PHEV).
One hybrid transmission configuration is a power-split hybrid. A power-split hybrid includes two electric machines. One of the electric machines is typically called the generator and the other is typically called the motor, although both are reversible electric machines. A planetary gearset distributes power from an internal combustion engine between the generator and the transmission output. The motor drives the transmission output. When the internal combustion engine is off, the motor can propel the vehicle using energy stored in the battery. During braking, the motor can converter vehicle kinetic energy to electrical energy for storage in the battery for later use. In some operating modes, the planetary gearset sends a portion of the power from the engine to the output via a mechanical power flow path and sends the remainder of the power to the generator which converts it to electrical power. The electrical power may be stored in the battery for later use, sent to the motor to supplement the power transferred via the mechanical power flow path, or some combination of the two. In other operating modes, typically associated with high vehicle speeds, the planetary gearset may draw power from the generator and send power from both the generator and the internal combustion engine to the output via the mechanical power flow path. The electrical energy to drive the generator in these modes may be drawn from the battery, from the motor, or from some combination of the two. Due to recirculation of power through the mechanical power flow path, the motor, and the generator, efficiency in these operating modes tends to be lower.
SUMMARY OF THE DISCLOSURE
A transmission includes an output, a first electric machine, and a first planetary gearset. The output is supported on a front side of a center housing while a stator of the first electric machine is fixed to the center housing and a rotor of the first electric machine is supported on a rear side of the center housing. A sun of the first planetary gearset is fixedly coupled to the rotor of the first electric machine, a carrier of the first planetary gearset is fixedly coupled to the output, and a ring of the first planetary gearset is fixedly held against rotation. The first planetary gearset may be located on the front side of the output. A rear housing may support rotor of a second electric machine. The rotors of the first and second machines may rotate about the same axis. A second planetary gearset may be located axially between the first and second rotors and radially inside the first and second stators. A sun of the second planetary gearset may be fixedly coupled to the rotor of the second electric machine. A carrier of second planetary gearset may be fixedly coupled to an input. A ring of the second planetary gearset may be fixedly coupled to an intermediate shaft. A front housing may support the input shaft and convey pressurized fluid to at least one hydraulically actuated clutch. One embodiment includes a third planetary gearset having a sun gear coupled to the front housing, a carrier coupled to the input, and a ring gear coupled to the output. Two of the planetary gearset elements may be fixedly coupled while the third is selectively coupled by the hydraulically actuated friction clutch. In a second embodiment, one friction clutch selectively couples the intermediate shaft to the output, another friction clutch selectively couples the intermediate shaft to the sun of the first planetary gearset, and a friction brake selectively holds the intermediate shaft against rotation.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic diagram of a first hybrid electric transmission arrangement.
FIG. 2 is a cross sectional view of a rear portion of the hybrid electric transmission arrangement of FIG. 1 .
FIG. 3 is a cross sectional view of a front portion of the hybrid electric transmission arrangement of FIG. 1 .
FIG. 4 is a schematic diagram of a second hybrid electric transmission arrangement.
FIG. 5 is a cross sectional view of a front portion of the hybrid electric transmission arrangement of FIG. 4 .
DETAILED DESCRIPTION
Embodiments of the present disclosure are described herein. It is to be understood, however, that the disclosed embodiments are merely examples and other embodiments can take various and alternative forms. The figures are not necessarily to scale; some features could be exaggerated or minimized to show details of particular components. Therefore, specific structural and functional details disclosed herein are not to be interpreted as limiting, but merely as a representative basis for teaching one skilled in the art to variously employ the present invention. As those of ordinary skill in the art will understand, various features illustrated and described with reference to any one of the figures can be combined with features illustrated in one or more other figures to produce embodiments that are not explicitly illustrated or described. The combinations of features illustrated provide representative embodiments for typical applications. Various combinations and modifications of the features consistent with the teachings of this disclosure, however, could be desired for particular applications or implementations.
Two elements are fixed to one another if they are directly fastened together without intermediate parts. The elements may be fixed by spline connections, welding, press fitting, machining from a common solid, bolts, or other means. A group of elements are fixedly coupled to one another if they are constrained to rotate, or to not rotate, at the same speed about the same axis in all operating conditions. Elements may be fixedly coupled via intermediate parts. Slight variations in rotational displacement between fixedly coupled elements can occur such as displacement due to lash or shaft compliance. In contrast, two elements are selectively coupled by a clutch when the clutch constrains them to rotate, or not rotate, at the same speed about the same axis whenever the clutch is fully engaged and they are free to rotate at distinct speeds in at least some other operating condition. A clutch that holds an element against rotation by selectively coupling the element to a stationary housing may be called a brake. A group of elements are coupled if they are either fixedly coupled or selectively coupled.
A first power-split hybrid electric transmission is illustrated schematically in FIG. 1 . Input 10 is driven by an internal combustion engine. Output 12 drives the vehicle wheels via a differential on an offset axis. Power may be transferred from output 12 to the differential by a chain and sprocket or by axis transfer gearing. Motor 14 includes a stator 16 fixedly and a rotor 18 . Stator 16 is held against rotation by transmission case 20 , which is mounted to vehicle structure. Gearset 22 includes a sun gear 24 fixedly coupled to rotor 18 , a ring gear 26 fixedly held against rotation, a carrier 28 fixedly coupled to output 12 , and a set of planet gears 30 supported for rotation with respect to carrier 28 and meshing with both sun gear 24 and ring gear 28 . Generator 32 includes a stator 34 and a rotor 36 . Simple planetary gearset 38 includes a sun gear 40 fixedly coupled to rotor 36 , a ring gear 42 fixedly coupled to intermediate shaft 44 , a carrier 46 fixedly coupled to input 10 , and a set of planet gears 48 supported for rotation with respect to carrier 46 and meshing with both sun gear 40 and ring gear 42 . Intermediate shaft 44 is fixedly coupled to output 12 via carrier 28 .
Motor 14 drives output 12 via planetary gearset 22 , which provides torque multiplication. When the internal combustion engine is off, motor 14 can propel the vehicle using energy stored in a battery. During braking, motor 14 can converter vehicle kinetic energy to electrical energy for storage in the battery. Planetary gearset 38 distributes power from input 10 between generator 32 and output 12 . Planetary gearset 38 also establishes a speed relationship among rotor 36 , input 10 , and intermediate shaft 44 . A controller can adjust the speed of rotor 36 by adjusting the electrical current to stator 34 . By adjusting the speed of rotor 36 , the controller can vary the speed ratio between input 10 and output 12 to any desired value between lower and upper limits. In some operating modes, in which rotor 36 rotates in the same direction as input 10 , planetary gearset 38 sends a portion of the input power to output 12 and sends the remainder of the power to generator 32 which converts it to electrical power. The electrical power may be stored in the battery for later use, sent to motor 14 to propel the vehicle, or some combination of the two. In other operating modes, in which rotor 36 and input 10 rotate in the opposite directions, planetary gearset 38 may draw power from generator 32 and send power from both generator 32 and input 10 to the output 12 . The electrical energy to drive generator 32 in these modes may be drawn from the battery, from motor 14 , or from some combination of the two.
The hybrid electric transmission of FIG. 1 also provides a fixed overdrive operating mode. Simple planetary gearset 50 includes a sun gear 52 fixedly held against rotation, a ring gear 54 , a carrier 56 fixedly coupled to input 10 , and a set of planet gears 58 supported for rotation with respect to carrier 56 and meshing with both sun gear 52 and ring gear 54 . Clutch 60 selectively couples ring gear 58 to output 12 via carrier 28 . When clutch 60 is engaged, out 12 is constrained to rotate at a fixed multiple of the speed of input 10 . Power may be transferred from input 10 to output 12 via gearset 50 and clutch 60 without use of either generator 32 or motor 14 . This direct mechanical power transfer is more efficient than converting a portion of the power to electrical form in one electric machine and then back to mechanical form in the other electrical machine. Although the engine may be slightly less efficient because the engine speed is not optimized, there are many circumstances in which the overall efficiency is improved by use of the fixed ratio operating mode. While operating in this fixed ratio mode, generator 32 and/or motor 14 may be used to add power for improved performance or to divert some power to the battery for later use.
FIG. 2 shows a cross section of a rear portion of a transmission according to the arrangement illustrated schematically in FIG. 1 . Rear refers to the side opposite the end of the transmission through which the input shaft extends. Front refers to the side toward the end through which the input extends. A center housing 62 supports a number of the components. A housing is a single piece of the transmission structure. Typically, a housing is formed by casting or forging metal into a shape close to the final desired shape, but having some additional material in certain areas. Then, excess material is removed in critical areas using more precise types of machining in order to produce a finished housing having low part-to-part variation with respect to critical dimensions. A transmission case may include multiple housings fastened together with removable fasteners such as bolts. This makes the housings easier to produce and permits assembly of components into areas that would be inaccessible if the transmission case were manufactured in a single piece. Output 12 is supported for rotation by center housing 62 on a front side of center housing 62 . Output 12 may be a sprocket meshing with chain 64 to transfer power to the differential assembly on another axis. Stator 16 is fixed to center housing 62 on a rear side of center housing 62 . Motor shaft 66 is supported for rotation by center housing 62 and extends from the front side to the rear side of center housing 62 . Rotor 18 is welded to rotor shaft 66 on the rear side of center housing 62 while sun gear 24 is splined to rotor shaft 66 on the front side of center housing 62 .
Rear housing 68 is bolted to flange 70 of center housing 62 . A leg of rear housing 68 supports generator shaft 72 for rotation. In some embodiments, the split line between center housing 62 and rear housing 68 may be shifted toward the front such that stator 34 is fixed to rear housing 68 instead of center housing 62 to reduce part-to-part variability of the air gap distance between stator 34 and rotor 36 . Stator 34 is fixed to center support 62 and rotor 36 is welded to generator shaft 72 . Sun gear 40 is splined to generator shaft 72 , carrier 46 is splined to input shaft 10 , and ring gear 42 is splined to intermediate shaft 44 . Planetary gear set 38 is nested inside rotors 18 and 36 to reduce axial length.
FIG. 3 shows a cross section of a front portion of a transmission according to the arrangement illustrated schematically in FIG. 1 . Front housing 76 is bolted to center housing 62 through flange 76 of center housing 62 and flange 78 of front housing 72 . Carrier 28 is splined to output 12 , intermediate shaft 44 , and clutch housing 80 of clutch 60 . Sun gear 52 is splined to a leg of front housing 74 . Carrier 56 is splined to input shaft 10 . Ring gear 54 is splined to a hub of clutch 60 . Front housing 74 is also fixed to valve body 82 . Front housing 74 defines fluid passageways 84 that carry fluid from valve body 82 to clutch 60 . One passageway carries fluid to an apply chamber. To engage clutch 60 , the fluid is this passageway is pressurized forcing a piston to compress a clutch pack. A second passageway carries unpressurized fluid to a balance chamber.
A second power-split hybrid electric transmission is illustrated schematically in FIG. 4 . Parts that are common with the transmission of FIG. 1 are labeled with the same reference number. Unlike the transmission of FIG. 1 , intermediate shaft 44 is not fixedly coupled to output 12 . Clutches 86 and 88 and brake 90 provide the modes of operation. Clutch 86 selectively couples intermediate shaft 44 to sun gear 24 . Engaging clutch 86 selects a low mode. In low mode, the mechanical power flow path from power-split gearset 38 utilizes gearset 22 to provide torque multiplication. Clutch 88 selectively couples intermediate shaft 44 to output 12 . Engaging clutch 88 selects a high mode, which functions the same as the transmission of FIG. 1 with clutch 60 disengaged. Brake 90 selectively holds intermediate shaft 44 against rotation. Engaging brake 90 selects a series mode. In series mode, there is no mechanical power flow path from power-split gearset 38 to the output. Rotor 36 is constrained to rotate at fixed multiple of the speed of input 10 . Generator 32 converts all of the input power into electrical power. Motor 16 provides all of the power to propel the vehicle, using some combination of stored electrical power from the battery and electrical power from generator 32 .
The rear portion of the transmission of FIG. 4 is identical to the rear portion of the transmission of FIG. 1 as shown in FIG. 2 . FIG. 5 shows a cross section of a front portion of a transmission according to the arrangement illustrated schematically in FIG. 4 . Parts that are common with the transmission of FIG. 3 are labeled with the same reference number. Intermediate shaft 44 is splined to clutch housing 92 . Front housing 74 includes a series of fluid passageways 84 from valve body 82 to various shift elements One passageway carries fluid to an apply chamber of clutch 86 . Another passageway carries fluid to an apply chamber of clutch 88 . A third passageway carries unpressurized fluid to balance chambers of clutches 86 and 88 . A fourth passageway carrier fluid to an apply chamber of brake 90 which is integrated into the front housing 74 .
While exemplary embodiments are described above, it is not intended that these embodiments describe all possible forms encompassed by the claims. The words used in the specification are words of description rather than limitation, and it is understood that various changes can be made without departing from the spirit and scope of the disclosure. As previously described, the features of various embodiments can be combined to form further embodiments of the invention that may not be explicitly described or illustrated. While various embodiments could have been described as providing advantages or being preferred over other embodiments or prior art implementations with respect to one or more desired characteristics, those of ordinary skill in the art recognize that one or more features or characteristics can be compromised to achieve desired overall system attributes, which depend on the specific application and implementation. As such, embodiments described as less desirable than other embodiments or prior art implementations with respect to one or more characteristics are not outside the scope of the disclosure and can be desirable for particular applications. | A family of hybrid electric transmission arrangements share a common center housing, rear housing, two electric machines, power-split planetary gearset, and torque multiplication gearset. One arrangement additionally utilizes an overdrive gearset and an overdrive clutch. Another arrangement additionally utilizes two clutches and a brake to implement three operating modes. Since the components that differ between the two arrangements use the same general packaging space and all shift elements are hydraulically controlled via a front housing, the design of the front housing is also similar. | 8 |
CROSS REFERENCE TO RELATED APPLICATION
This application is a continuation of U.S. patent application Ser. No. 14/642,607, filed Mar. 9, 2016, which itself is a continuation of U.S. patent application Ser. No. 13/398,611, filed Feb. 16, 2012, now U.S. Pat. No. 8,975,822, which itself is a continuation of U.S. patent application Ser. No. 12/188,233, filed Aug. 8, 2008, now U.S. Pat. No. 8,134,300. The foregoing applications are incorporated herein by reference in their entireties as if fully set forth herein.
FIELD OF THE INVENTION
The present invention relates to portable lighting devices, including, for example, flashlights and headlamps, and their circuitry.
BACKGROUND
Various handheld or portable lighting devices, including flashlights, are known in the art. Flashlights typically include one or more dry cell batteries having positive and negative electrodes. In certain flashlights, the batteries are arranged in series in a battery compartment of a barrel or housing that can be used to hold the flashlights. An electrical circuit is frequently established from a battery electrode through conductive means which are electrically coupled with an electrode of a light source, such as a lamp bulb or a light emitting diode (“LED”). After passing through the light source, the electric circuit continues through a second electrode of the light source in electrical contact with conductive means, which in turn are in electrical contact with the other electrode of a battery. Typically, the circuit includes a switch to open or close the circuit. Actuation of the switch to close the electrical circuit enables current to pass through the lamp bulb, LED, or other light source—and through the filament, in the case of an incandescent lamp bulb—thereby generating light.
Conventional flashlights also frequently include a head assembly, which typically includes a head, a lens, a face cap, and a reflector. The face cap in such flashlights is typically attached to the head to hold the lens and reflector relative to the head. Head assemblies of this type are often threadably mounted to the forward end of the body or barrel of the flashlight via the head. Such head assemblies are not conducive, however, to accessing a light source alignment device, such as the light source alignment devices included in the flashlights described in U.S. Pat. No. 7,264,372 B2 (“the '372 patent”) or U.S. Patent Publication 2007/0064354 A1 (“the '354 publication”), both of which are assigned to MAG Instrument, Inc.
The '372 patent teaches a head assembly including a face cap, lens, a sleeve or skirt, and a sealing O-ring that are configured and arranged so that the face cap and sleeve define a clearance envelope surrounding the flange of a reflector module to solve this problem. As a result, the head assembly may be rotated about the axis of the flashlight relative to reflector module so as to cause the light source to translate along the axis of the reflector and vary the dispersion of light produced by the flashlight. Further, the user may disengage the sleeve or skirt from the face cap and then slide it rearward to gain access to the light source alignment device and thereby move the light source in one or more directions lateral to the axis of the reflector to align the substantial point source of light with the axis of the reflector. The disadvantage of this construction is that when the sleeve or skirt is disengaged from the face cap, the face cap, and hence the lens, are no longer connected to the reflector module or any other portion of the flashlight, and hence they are liable to be dropped and/or damaged.
The flashlight described in the '354 publication solves this problem through the use of a support structure to which the face cap and skirt (which is referred to as the head in the '354 publication) are separately attached. The face cap is threadably attached to the support structure of the flashlight and retains the lens and reflector relative to the support structure. Thus, when the skirt is detached from the support structure to gain access to the light source alignment device included in the flashlight of the '354 publication, the face cap and associated optics remain attached to the flashlight, thereby minimizing the potential for damage to the same. However, the skirt of the '354 patent publication is attached to the support structure via a compressible retaining ring. More particularly, the internal surface of the skirt is configured to mate with the outer surface of the support structure of the flashlight at select locations to properly position the skirt relative to the face cap and the support structure. The compressible retaining ring is then provided in a channel extending around the outer surface of the support structure to create an interference fit with a feature provided on the internal surface of the skirt. Because the skirt must be removable in order for the user to access the light source alignment device included in the flashlight described in the '354 publication, however, the compressible retaining ring may not provide a permanent type interference fit. Indeed, to permit the average user to remove the skirt without undue effort, the interference fit must be relatively weak. As a result, the skirt of this flashlight is subject to being unintentionally disconnected from the support structure if the flashlight is dropped on its tail or otherwise receives a jolt to the tail of the flashlight. The unintentional detachment of the skirt from the support structure in this manner is undesirable.
Although the '372 patent and '354 publication indicate that the light source employed in the flashlights described in each of the patent documents may be an LED, these patent documents do not teach a configuration that suitably addresses the thermal management issues created by high power, high brightness LEDs.
Some advanced portable lighting devices provide multiple functions for different needs. For example, a power saving mode and/or an SOS mode may be implemented in a flashlight or other portable lighting devices in addition to the normal “full power” mode. In such portable lighting devices, the user typically elects the desired mode of operation by manipulation of the main power switch. For example, when the flashlight is in the normal mode or the power save mode of operation, the flashlight may be transitioned to another mode of operation, such as an SOS mode by manipulating the main power switch to momentarily turn off and then turn back on the flashlight.
Typically the functionality of multi-mode portable lighting devices of this sort is provided by a microcontroller, which remains powered by the batteries at all times. As a result, the volatile memory of the microcontroller may be used to remember the current mode of the flashlight, and thus determine which mode to transition into in the event that a user enters the proper command signal. However, if the portable lighting device—particularly in the case of larger flashlights—is accidentally hit against or dropped on a hard surface, the inertia of the battery or batteries may cause the battery or batteries to disconnect from one of the battery contacts for a short period of time. This disconnection will also cause a power loss to the microcontroller, thereby causing the microcontroller to lose track of the mode the flashlight or other lighting device was in prior to the power loss. As a result, the microcontroller will reset the flashlight or other lighting device to its default mode, which is typically off, rather than automatically returning to the prior mode of operation. Resetting under such circumstances is undesirable and potentially hazardous.
Portable lighting devices that include advanced functionality typically include a printed circuit board with a microcontroller or microprocessor to provide the desired functionality. A need exists, however, for a push button switch assembly that includes an integral circuit board that may be readily employed in a variety of portable lighting devices to provide multiple levels of functionality to the same.
In view of the foregoing, a need exists for an improved technique of attaching a flashlight skirt to the flashlight while also providing a user friendly operation when detaching the skirt. A separate need also exists for an improved portable lighting device that addresses or at least ameliorates one or more of the problems discussed above.
SUMMARY
The present invention is generally directed to a flashlight which can operate in multiple modes of operation in which temporary disconnection of the electrical circuit which controls the modes of operation, for less than a preselected period of time, will not lose a selected desired mode of operation, while a default mode of operation is selected if the electrical circuit is disconnected for longer than the preselection period of time (such as 0.5 seconds or less).
Further aspects, objects, and desirable features, and advantages of the invention will be better understood from the following description considered in connection with the accompanying drawings in which various embodiments of the disclosed invention are illustrated by way of example. It is to be expressly understood, however, that the drawings are for the purpose of illustration only and are not intended as a definition of the limits of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a top view of a flashlight according to one embodiment of the present invention.
FIG. 2 is a cross-sectional view of the flashlight of FIG. 1 , taken along the plane indicated by 102 - 102 .
FIG. 3 is an enlarged cross-sectional view of the forward section of the flashlight of FIG. 1 taken through the plane indicated by 102 - 102 .
FIG. 4 is an exploded perspective view of the flashlight of FIG. 1 .
FIG. 5A is an enlarged exploded perspective view of a portion of the head assembly of the flashlight of FIG. 1 . FIG. 5B is an enlarged exploded perspective view of the adjustable ball assembly portion of the flashlight of FIG. 1 . FIG. 5C is an enlarged exploded perspective view of the switch assembly portion of the flashlight of FIG. 1 .
FIGS. 6A through 6C are different cross-sectional views illustrating one relative position between the skirt lock ring and head. FIGS. 6D through 6F are different cross-sectional views illustrating a second relative position between the skirt lock ring and head. FIGS. 6G through 6I are different cross-sectional views illustrating a third relative position between the skirt lock ring and head.
FIG. 7 is a cross-sectional view of a flashlight according to another embodiment of the present invention.
FIG. 8 is an exploded perspective view of the adjustable ball assembly portion of the flashlight of FIG. 7 .
FIG. 9 is a circuit diagram illustrating the relationship of the electronic circuitry according to one embodiment of the invention.
FIGS. 10A-E are schematic circuit diagrams of different components of the circuit shown in FIG. 9 .
FIGS. 11A-C are diagrams of the power profile for different types of batteries.
DETAILED DESCRIPTION
Embodiments of the invention will now be described with reference to the drawings. To facilitate the description, any reference numeral representing an element in one figure will represent the same element in any other figure. Further, in the description that is to follow, upper, front, forward or forward facing side of a component shall generally mean the orientation or the side of the component facing the direction toward the front end of the portable lighting device or flashlight. Similarly, lower, aft, back, rearward or rearward facing side of a component shall generally mean the orientation or the side of the component facing the direction toward the rear of the portable lighting device, (e.g. where the tail cap is located in the case of a flashlight).
Flashlights 100 , 300 according to different embodiments of the present invention are described in connection with FIGS. 1-11C below. Each of the flashlights 100 , 300 incorporate a number of distinct aspects of the present invention. While these distinct aspects have all been incorporated into the flashlight 100 , 300 in various combinations, it is to be expressly understood that the present invention is not restricted to flashlights 100 , 300 described herein. Rather, the present invention is directed to each of the inventive features of the flashlights 100 , 300 described below individually as well as collectively. Further, as will become apparent to those skilled in the art after reviewing the present disclosure, one or more aspects of the present invention may also be incorporated into other portable lighting devices, including, for example, headlamps.
Referring to FIGS. 1-2 , flashlight 100 includes a barrel 198 enclosed at a rearward end by a tail cap 206 and at a forward end by a head assembly 210 .
Barrel 198 is preferably made out of aluminum. As is known in the art, barrel 198 may be provided with a textured surface 104 along its axial extent, preferably in the form of machined knurling. A portion of forward end 110 of barrel 198 extends beneath head skirt 194 . A compartment 199 is formed in barrel 198 to hold a portable power source, such as one or more batteries in series, or a battery pack with cells arranged in series or parallel. Further, the employed batteries or battery pack may be rechargeable.
Tail cap 206 is also preferably made out of aluminum and is configured to engage mating threads provided on the interior of barrel 198 as is conventional in the art. However, other suitable means may also be employed for attaching tail cap 206 to barrel 198 . A one-way valve 204 , such as a lip seal, may be provided at the interface between tail cap 206 and barrel 198 to provide a watertight seal while simultaneously allowing overpressure within the flashlight to expel or vent to atmosphere. However, as those skilled in the art will appreciate, other forms of sealing elements, such as an O-ring, may be used instead of one-way valve 204 to form a watertight seal. The design and use of one-way valves in flashlights is more fully described in U.S. Pat. No. 5,113,326 to Anthony Maglica, which is hereby incorporated by reference.
If made out of aluminum, the surfaces of barrel 198 and tail cap 206 are preferably anodized with the exception of those surfaces used to make electrical contact with another metal surface for purposes of forming the electrical circuit of the flashlight. In the present embodiment, an electrical path is formed between barrel 198 and the case electrode of the batteries or battery pack installed in the compartment 199 by spring 202 and tail cap 206 . In addition to forming part of the electrical path between the barrel and case electrode, spring 202 also urges batteries or battery pack installed in the compartment 199 forward so that the center electrode of the front-most battery or battery pack is urged into one end of spring contact 174 .
Referring to FIGS. 1-4 , the present embodiment includes a head 120 to which a number of other components may be mounted, including, for example, skirt lock ring 126 , wave spring 122 , head skirt 194 , face cap 112 , lens 116 , and reflector 118 to form a head assembly 210 . Head 120 , skirt lock ring 126 , head skirt 194 and face cap 112 are preferably made from anodized aluminum. On the other hand, reflector 118 is preferably made out of injection molded plastic. The interior surface of reflector 118 is preferably metallized to enhance its reflectivity to a suitable level.
In the present embodiment, head 120 is a hollow support structure comprising a front section 216 , a midsection 218 and an aft section 230 . Head 120 is internally disposed in the present embodiment in that head 120 is covered by face cap 112 , skirt lock ring 126 , and head skirt 194 when the flashlight 100 is fully assembled. In other words, in the present embodiment, head 120 does not comprise an external portion of the flashlight 100 . The front section 216 comprises a generally cup-shaped receiving area 232 for receiving reflector 118 . The midsection 218 , which extends rearward from the front section 216 , includes a generally cylindrical inner surface 234 . And, the aft section 230 , which extends rearward from the midsection 218 , includes internal threads 236 which are configured to mate with external threads 197 on the forward end of barrel 198 . The head 120 is locked to the barrel 198 with retainer 132 . Retainer 132 is externally threaded with threads 240 on its aft end and is outwardly tapered on its forward end. Retainer 132 is configured so that external threads 240 mate with internal threads 195 provided on the forward end of barrel 198 . Because the forward end 110 of barrel 198 includes opposing slots 111 , when retainer 132 is threaded into threads 125 of barrel 198 , barrel 198 is expanded as the tapered portion of retainer 132 contacts barrel 198 and is then screwed further into the barrel 198 . When retainer 132 is fully seated in barrel 198 , head 120 is locked to the barrel 198 .
The face cap 112 retains lens 116 and reflector 118 relative to the head 120 and reflector 118 . In the present embodiment, face cap 112 is configured to thread onto external threads 238 provided on the front section 216 of the head 120 . In other implementations, however, other forms of attachment may be adopted. An O-ring 114 is provided at the interface between face cap 112 and lens 116 to provide a watertight seal. As best seen in FIG. 3 , reflector 118 is positioned within the cup-shaped receiving area 232 of head 120 so that it is disposed forward of the head 120 and retainer 132 . The internal surface of the cup-shaped receiving area 232 together with the outer surface of reflector 118 and reflector flange 119 ensure the proper alignment of the principal axis of reflector 118 with the central axis of the barrel 198 . The face cap 112 in turn clamps O-ring 114 , lens 116 , and reflector 118 via reflector flange 119 to head 120 .
Head skirt 194 has a diameter greater than that of the barrel 198 . Head skirt 194 is also adapted to pass externally over the exterior of the barrel 198 . The forward end 242 of head skirt 194 is configured to mate with the outer surface of a skirt lock ring 126 at select locations to properly position head skirt 194 relative to face cap 112 and head 120 .
The locking mechanism of the head skirt 194 will now be described. FIG. 5A shows an exploded view of a portion of head assembly 210 . The outer surface of head 120 has a normally smooth surface 266 with an annular groove 267 on the outer surface of aft section 230 and a plurality of protuberances 268 equally spaced from each other around the outer circumference of the midsection 218 of head 120 . As best seen in FIGS. 6C, 6F, and 6I , a gap 231 is formed between each protuberance 268 and the front section 216 of head 120 . In the present embodiment, six protuberances 268 are used. Each of the protuberances 268 has a cut 269 on the front end such that each of the protuberances 268 have a reversed L-shaped cross-section in the longitudinal direction of flashlight 100 as seen in FIG. 6C , for example. At the toe of the reversed L-shaped protuberances 268 is a lock member 270 . In the present embodiment, the number of protuberances 268 is six. In other embodiments, the number of protuberances 268 may be different. However, the number of protuberances 268 should be an integer number greater than or equal to three.
The inner surface of skirt lock ring 126 has a front end 281 , an aft end 282 and a middle portion 283 in between. The inner surface of skirt lock ring 126 comprises a plurality of longitudinal channels 271 formed by a plurality of first indexing bumps 272 and second indexing bumps 275 . In the present embodiment, six first indexing bumps 272 are formed near the middle portion 283 of the inner surface of the skirt lock ring 126 and six second indexing bumps 275 are formed near the aft end 282 of the inner surface of the skirt lock ring 126 . Each of the first indexing bumps 272 comprises two high plateau regions 274 separated by a low plateau region 273 . Similarly, each of the second indexing bumps 275 comprises two high plateau regions 277 separated by a low plateau region 276 . In the present embodiment, some of the high plateau regions 277 of the second indexing bumps 275 have a hole 278 sized to receive a ball 128 . In the present embodiment, three holes 278 are equally spaced from each other around the inner circumference of skirt lock ring 126 . In the present embodiment, the number of first indexing bumps 272 is the same as the number of second indexing bumps 275 . In an alternate embodiment, the number of first indexing bumps 272 may be an integer multiple of the number of second indexing bumps 275 . In another embodiment, the number of first indexing bumps 272 is an integer factor of the number of second indexing bumps 275 . In the present embodiment, the number of second indexing bumps 275 is the same as the number of protuberances 268 . In other embodiments, the number of second indexing bumps 275 may be an integer multiple of the number of protuberances 268 .
FIGS. 6A-C show different cross-sectional views through the head 120 and skirt lock ring 126 when the skirt lock ring 126 has been rotated to a position which unlocks the head skirt 126 axially from the head 120 . FIGS. 6A-6C also show skirt lock ring 126 in a position (position A) relative to head 120 where their aft ends are aligned. Balls 128 now sits in trench 267 and the top end 279 of ball 128 is lower than the top surface 280 near the aft end of skirt lock ring 126 . Accordingly, head skirt 194 can be freely mounted to or dismounted from skirt lock ring 126 at this position. When every protuberance 268 of head 120 is aligned with a channel 271 of skirt lock ring 126 (as shown in FIG. 6C ) by rotating skirt lock ring 126 to a suitable position, then the first indexing bumps 272 and the second indexing bumps 275 are aligned with the smooth surface 266 of skirt lock ring 126 (as shown in FIGS. 6A-6B ). In this position, skirt lock ring 126 may be freely moved axially forward or rearward over head 120 . FIG. 6A more particularly shows where low plateau regions 273 , 276 of skirt lock ring 126 are aligned with the smooth surface 266 of head 120 , and FIG. 6B more particularly shows where high plateau regions 274 , 277 of skirt lock ring 126 are aligned with the smooth surface 266 of head 120 . When the skirt lock ring 126 is indexed to this position, it is in a position in which it may be moved forward or rearward relative to head 120 by an operative amount. However, skirt lock ring 126 can not be rotated relatively to head 120 because protuberances 268 and high plateau regions 274 are next to each other so that high plateau regions 274 extend too far out from skirt locking ring 126 to pass over protuberances 268 .
When skirt lock ring 126 and head 120 are aligned as illustrated in FIGS. 6A-6C , skirt lock ring 126 may be pushed forward to position B against the spring force of wave spring 122 , as shown in FIGS. 6D-6F . When skirt lock ring 126 is pushed forward in this manner protuberances 268 and high plateau regions 274 are no longer next to each other. As a result, skirt lock ring 126 can now be rotated relative to head 120 because high plateau regions will now pass through gap 231 between protuberance 268 and the front section 216 of head 120 as skirt lock ring 126 is rotated. Balls 128 , however, no longer sit in trench 267 , but instead are disposed on the smooth surface 266 . As a result, the top end 279 of ball 128 is now higher than the top surface 280 near the aft end of skirt lock ring 126 . If the head skirt 194 is mounted to the skirt lock ring 126 , the ball 128 will extend into annular groove 129 formed in the interior surface of head skirt 194 . However, because protuberances 268 remain aligned with channels 271 , the skirt lock ring 126 remains subject to being moved rearward to position A shown in FIGS. 6A-6C and thus the head skirt 194 is not axially locked to the head 120 at this point.
When skirt lock ring 126 and head 120 are aligned as described in FIGS. 6D-6F , skirt lock ring 126 can be rotated relatively to head 120 . If a user rotates skirt lock ring 126 30° in either direction and then releases the skirt lock ring 126 wave spring 122 will bias the skirt lock ring 126 rearward, and the relationship between skirt lock ring 126 and head 120 will be the position (position C) as shown in FIGS. 6G-6I . Now, protuberances 268 are aligned with low plateau regions 273 (as shown in FIG. 6I ). Further, the spring force of wave spring 122 pushes skirt lock ring 126 rearward until a corner of each low plateau region 273 fits into a cut 269 of an opposing protuberance 268 and lock members 270 are positioned under the low plateau regions 273 . In this manner, skirt lock ring 126 can not be rotated relatively to head 120 because each side of lock member 270 of protuberances 268 is now next to a high plateau region 274 . In addition, balls 128 are still disposed on the smooth surface 266 , and, as a result, the top end 279 of ball 128 is still higher than the top surface 280 near the aft end of skirt lock ring 126 . Thus, if head skirt 194 is mounted, it will be axially locked by ball 128 to head 120 and can not be dismounted (as shown in FIGS. 2-3 ).
When head skirt 194 is locked (as shown in FIGS. 2-3 ), the skirt lock ring 126 and head 120 are aligned as illustrated in FIGS. 6G-6I . To access adjusting ring 148 to adjust the alignment of the beam direction of the substantial point source of light, namely LED 145 of LED module 144 in the present embodiment, with the principal axis of the reflector, head skirt 194 must be unlocked and slid rearward over barrel 198 at least far enough for the user to gain access to adjustment ring 148 . The procedure for accomplishing this is described below.
First, when head skirt 194 is axially locked to the head 120 by the skirt locking ring 126 , the skirt lock ring 126 and head 120 are aligned as illustrated in FIGS. 6G-6I . Further, skirt lock ring 126 can not be rotated relative to head 120 . However, the head skirt 194 is free to rotate about the skirt locking ring 126 and barrel 198 to axially translate the light source along the axis of the reflector as discussed more fully below. Further, the skirt lock ring 126 together with the head skirt 194 may be pushed forward against wave spring 122 to unlock skirt lock ring 126 from head 120 . By rotating the skirt lock ring 126 30° in either direction, the skirt lock ring 126 and head 120 are aligned as illustrated in FIGS. 6D-6F , and, as a result, the head skirt 194 is axially unlocked from the head member 194 and thus may be removed from the flashlight 100 . This is because skirt lock ring 126 is now free to move from position B to position A, and once skirt lock ring 126 and head 120 are aligned in position A, as shown in FIGS. 6A-6C , balls 128 will fall into trench 267 and the top end 279 of balls 128 will no longer be higher than the top surface 280 near the aft end of skirt lock ring 126 . Accordingly, head skirt 194 may continue to be moved rearward and dismounted. It is no longer locked by ball 128 and head skirt 194 can now be dismounted. However, cam 188 will block skirt lock ring 126 from moving rearward beyond its position in position A.
If it is desired to mount head skirt 194 back to have a complete flashlight assembly, the following procedure can be used. First, head skirt 194 is slid forward over the flashlight barrel 198 until it abuts skirt lock ring 126 . Once head skirt 194 abuts skirt lock ring 126 , head skirt 194 together with skirt lock ring 126 may be pushed forward to position B against the spring force of wave spring 122 , as shown in FIGS. 6D-6F . Balls 128 are now disposed on the smooth surface 266 and the top end 279 of ball 128 is higher than the top surface 280 near the aft end of skirt lock ring 126 so as to extend into annular groove 129 in head skirt 194 .
Once in position B, skirt lock ring 126 may be rotated 30° in either direction and then released. Wave spring 122 will bias the skirt lock ring 126 rearward so that the skirt lock ring 126 and head 120 are placed in position C as shown in FIGS. 6G-6I . At this point, skirt lock ring 126 can no longer be rotated because lock members 270 of protuberances 268 are now locked by high plateau regions 274 . Because balls 128 are now disposed on the smooth surface 266 , as shown in FIG. 6H and skirt lock ring 126 can not be rotated, head skirt 194 is axially locked to the head 120 and can not be dismounted (as shown in FIGS. 2-3 ).
Referring back to FIGS. 1-4 , an O-ring 124 is provided at the interface between face cap 112 and skirt lock ring 126 to provide a watertight seal.
A one-way valve 130 , such as a lip seal, may be provided at the interface between the head skirt 194 and skirt lock ring 126 to provide a watertight seal and to prevent moisture and dirt from entering head and switch assembly 106 between skirt lock ring 126 and the forward end 242 of head skirt 194 .
As noted above, a portion of the forward end 110 of barrel 198 is disposed under head skirt 194 when it is mounted to the flashlight 100 . The forward most portion of the forward end 110 is interposed between, and threadably attached to, the aft section 230 of the head 120 and retainer 132 as explained above. As a result of the foregoing construction, with the exception of the external surface formed by switch cover 200 , all of the external surfaces of the flashlight 100 according to the present embodiment may be made out of metal, and more preferably aluminum.
The forward end 110 of barrel 198 is provided with a hole 244 through which a seal or switch cover 200 extends. The outer surface of forward end 110 of barrel 198 surrounding switch cover 200 may be beveled to facilitate tactile operation of flashlight 100 . Forward end 110 of barrel 198 may also be provided with a groove 246 about its circumference at a location forward of the trailing edge 248 of head skirt 194 for positioning a sealing element 196 , such as an O-ring, to form a watertight seal between the head skirt 194 and barrel 198 . Similarly, switch cover 200 is preferably made from molded rubber. As best illustrated in FIG. 3 , switch cover 200 is preferably configured to prevent moisture and dirt from entering the head and switch assembly 106 through hole 244 .
Referring to FIG. 5B , the components of an adjustable ball assembly 212 according to the present embodiment are illustrated. In the present embodiment, a lamp or other light source, such as LED 145 of LED module 144 , is mounted within head and switch assembly 106 so as to extend into reflector 118 through a central hole provided therein. In particular, LED module 144 is mounted on adjustable ball assembly 212 , which in turn is slideably mounted within the forward end 110 of barrel 198 . The adjustable ball assembly 212 is prevented from sliding out of the forward end 110 of barrel 198 by retainer 132 , head 120 , and cam assembly 188 , 190 and cam follower assembly 135 . In the present embodiment, cam follower assembly 135 includes a cam follower screw 134 , a cam follower roller 136 , and a cam follower bushing 138 .
An LED module that may be used for LED module 144 is described in co-pending U.S. patent application Ser. No. 12/188,201, filed Aug. 7, 2008, by Anthony Maglica et al., the contents of which is hereby incorporated by reference.
Referring to FIGS. 3 and 4 , when adjustable ball assembly is positioned inside the front end 110 of barrel 198 and the cam follower assembly 135 is positioned in one of the axial slots 111 the radial arms of adjusting ring 148 will extend through the opposing slots 110 on the front end 110 of barrel 198 . Further, the reflector 118 is sized so that the LED module 144 held by the adjustable ball assembly 212 is positioned adjacent the central opening in the aft end of reflector 118 .
Still referring to FIG. 3 , the moveable cam assembly 188 , 190 is sized to fit around the outer diameter of the barrel 198 . Front cam half 188 and rear cam half 190 form the cam assembly 188 , 190 which is generally a barrel cam with a curved cam channel 250 that extends around the inner circumference of the cam assembly 188 , 190 . The cam assembly 188 , 190 is also sized such that when installed, the cam follower roller 136 of the cam follower assembly 135 engages with cam channel 250 . Accordingly, the cam channel 250 is able to define the axial rise, fall, and dwell of the adjustable ball assembly 212 . This is because the cam follower assembly 135 is able to slide in the curved cam channel 250 of the cam assembly 188 , 190 when cam assembly 188 , 190 is rotated.
The cam assembly is held longitudinally in place between the aft end of head 120 and snap ring 192 . Because the curved cam channel 250 is disposed transverse to the axis of the flashlight 100 , when cam assembly 188 , 190 is rotated, ball housing 140 (along with LED module 144 ) will move forwards and backwards along the longitudinal direction of flashlight 100 , changing the dispersion of light created by the flashlight from spot to flood and then from flood to spot.
In the present embodiment, forward end 110 of barrel 198 preferably includes a groove 252 about its circumference for positioning external snap ring 192 to keep the cam assembly 188 , 190 from moving toward the rear direction of the flashlight 100 .
Cam assembly 188 , 190 is preferably a two piece construction so that the separate halves may be fitted over the outer diameter of the flashlight barrel 198 and the cam follower assembly 135 . The tow pieces of the moveable cam assembly 188 , 190 may be secured together by any suitable method. Preferably, the respective cam halves are formed to snap together.
Referring to FIG. 4 , longitudinal locking ribs are provided on the outer diameter of the cam assembly 188 , 190 . Preferably the locking ribs are equally spaced around the outer circumference of the cam assembly. Corresponding longitudinal locking slots are provided on the interior surface of the head skirt 194 . As a result, when head skirt 194 is mounted on the flashlight 100 and it is rotated about the axis of the barrel 198 , cam assembly 188 , 190 will also be caused to rotate about the barrel 198 . Rotation of the cam assembly 188 , 190 in turn will cause the adjustable ball assembly 212 to axially displace along the inside of reflector 118 . In this way, the LED module 144 or other light source may be caused to translate along the reflector axis.
One of the electrode contacts, the positive electrode 254 in the present embodiment, of LED module 144 extends into a contact disc 146 where they are preferably frictionally engaged. Another electrode contact, the negative electrode 256 in the present embodiment, is configured to make electrical connection with the inner surface of ball 142 , which is preferably made out of metal. As previously described, the ball 142 is slideably mounted via ball housing 140 , which is also preferably made out of metal, within the front end 110 of barrel 198 .
Contact disc 146 is in electrical communication with an outer contact sleeve 158 . Outer contact sleeve 158 is slideably engaged with an inner contact sleeve 162 . A spring 160 is installed within the outer contact sleeve 158 and the inner contact sleeve 162 to allow relative movement between the outer contact sleeve 158 and the inner contact sleeve 162 while maintaining electrical communication between contact disc 146 and the aft end of inner contact sleeve 162 . In the present embodiment, the outer contact sleeve 158 , inner contact sleeve 162 , and spring 160 are preferably made out of metal.
Outer contact sleeve 158 is further slideably held by a non crush sleeve 156 , which in turn is held within a retainer 154 . Retainer 154 is in turn held by ball housing 140 . In the present embodiment, non crush sleeve 156 is preferably made out of metal while retainer 154 is preferably made out of non-conductive material, such as plastic.
An adjusting ring 148 is located between retainer 154 and contact disk 146 to slightly adjust the axial direction of LED module 144 , and hence LED 145 . Adjusting ring 148 is supported by a push cup 150 . Push cup 150 is located between the adjusting ring 148 and retainer 154 . In the present embodiment, a wave spring 152 is further inserted between the push cup 150 and retainer 154 to provide cushion.
Inner contact sleeve 162 is frictionally held by main switch housing 176 so that the aft end of inner contact sleeve 162 is in electrical communication with an assembled circuit board 172 at via 258 .
Referring to FIGS. 3, 4 and 5C which shows components of a switch assembly 214 , switch assembly 214 preferably includes a main switch housing 176 and a user interface, which is a switch cover 200 in the present embodiment. Main switch housing 176 encloses an upper switch housing 166 , an actuator 168 , a snap dome 170 , an assembled circuit board 172 , a snap in contact 174 , a lower switch housing 178 , a switch spring 180 , a set screw 182 , a ground contact 184 , and a hex nut 186 . In the present embodiment, snap in contact 174 , switch spring 180 , set screw 182 , ground contact 184 , and hex nut 186 are preferably made out of metal while main switch housing 176 , upper switch housing 166 , actuator 168 , and lower switch housing 178 are preferably made out of non-conductive material, such as plastic.
Referring to FIG. 5C , in the present embodiment, the snap dome 170 has four legs with one leg 282 shorter than other three legs 283 , 284 , 285 . The legs 283 , 284 , 285 are used to contact to ground pads 286 , 287 , 288 on assembled circuit board 172 while the short leg 282 is used to contact with a momentary pad 289 on assembled circuit board 172 . A ring-shaped latch pad 290 is placed in the middle of the assembled circuit board 172 . In the present embodiment, the momentary pad 289 has a shorter distance from the center of assembled circuit board 172 than other three pads have.
When switch cover 200 is not depressed, short leg 282 is not in contact with any portions on assembled circuit board 172 . In this situation, both latch pad 290 and momentary pad 289 on assembled circuit board 172 are not in contact with ground pads 286 , 287 , 288 on assembled circuit board 172 .
When switch cover 200 is depressed half way down, actuator 168 pushes snap dome 170 toward assembled circuit board 172 . In this situation, Short leg 282 is contacting to momentary pad 289 while the central body of snap dome 170 is not contacting with latch pad 290 of assembled circuit board 172 . Since the whole snap dome 170 is made of metal, the momentary pad 289 is now connecting to ground while the latch pad 290 is not.
When switch cover 200 is further depressed, actuator 168 pushes snap dome 170 further down until snap dome 170 collapse such that the body of snap dome 170 is in contact with latch pad 290 . Now, not only momentary pad 289 is connecting to ground, latch pad 290 is also connecting to ground.
The condition whether momentary pad 289 or latch pad 290 is connecting to ground are received as signals to the assembled circuit board 172 , which in turn passes or disrupts the energy flow from the batteries in the battery compartment 199 to the aft end of inner contact sleeve 162 . In this way, head and switch assembly 106 can turn the flashlight 100 on or off. The assembled circuit board 172 may additionally include circuitry suitable for providing functions to the flashlight 100 which will be described in more detail later.
Snap in contact 174 is configured to include curved springs or biasing elements such that the assembled circuit board 172 is protected by the spring force generated by snap in contact 174 from, for example, batteries shifting and pressing on the main switch housing 176 . In this way, an effective electrical connection can be maintained by the biasing elements while protecting sensitive components, such as the assembled circuit board 172 .
Lower switch housing 178 is mounted with two L-shaped contacts 260 , 262 . L-shaped contact 260 is used to electrically contact with a positive contact of the assembled circuit board 172 while maintaining electrically contact with snap in contact 174 . L-shaped contact 262 is used to electrically contact with another positive contact of the assembled circuit board 172 while maintaining electrically contact with the aft end of inner contact sleeve 162 . In the present embodiment, once batteries are inserted into the battery compartment 199 , the center electrode of the forward-most battery (not shown) is electrically coupled to the snap in contact 174 , which is electrically coupled to the assembled circuit board 172 , which in turn is electrically coupled to the aft end of inner contact sleeve 162 .
Ground contact 184 is secured by hex nut 186 to electrically communicate with set screw 182 , which in turn is electrically coupled to switch spring 180 , which in turn is electrically coupled to a ground contact of the assembled circuit board 172 .
When batteries (not shown) are installed into the battery compartment 199 , in the present embodiment, an electrical current can flow from the center electrode of the forward-most battery to snap in contact 174 , L-shaped contact 260 , assembled circuit board 172 , switch spring 180 , set screw 182 , barrel 198 , tail cap 206 , spring 202 , and back to the case electrode of batteries. This electrical path provides electrical power to the components mounted on the assembled circuit board 172 .
Electrical current can also flow from the center electrode of the forward-most battery to snap in contact 174 , L-shaped contact 260 , assembled circuit board 172 , L-shaped contact 262 , inner contact sleeve 162 , spring 160 , outer contact sleeve 158 , contact disc 146 , LED module 144 , ball 142 , ball housing 140 , ground contact 184 , set screw 182 , barrel 198 , tail cap 206 , spring 202 , and back to the case electrode of batteries. This electrical path provides electrical power to the LED 145 of LED module 144 .
Referring to FIG. 7 , flashlight 300 has similar construction as that of flashlight 100 . The major difference is that, in flashlight 300 , incandescent lamp is preferred. Also, a spare lamp holder 208 for holding a spare lamp 209 is inserted in tail cap 206 .
FIG. 8 is a partially exploded view of the flashlight of FIG. 7 showing an adjustable ball assembly portion 361 which is corresponding to the adjustable ball assembly portion 212 of flashlight 100 shown in FIG. 5B . According to the embodiment of FIG. 8 , flashlight 300 has a ball 342 which can hold a contact holder 344 . The front end of contact holder 344 can receive two conductive pins from a lamp 341 . In the present embodiment, lamp 341 is a incandescent lamp. On the aft end of contact holder 344 is a lamp contact 346 which is integrally molded into contact holder 344 to form an assembly. The contact 346 serves the same function as the contact disc 146 of flashlight 100 that lamp contact 346 also forms a portion of an electric path between batteries (not shown) and lamp 341 . Other components of the ball assembly portion 361 are similar to that in flashlight 100 and would not be described further.
Assembled circuit board 172 will now be described. For the purpose of simplification, assembled circuit board 172 is described in connection with flashlight 100 . However, it is understandable that assembled circuit board 172 is also used in flashlights 300 , 400 , and 600 . FIG. 9 is a block diagram illustrating the relationship of the electronic circuitry of assembled circuit board 172 . In the embodiment of FIG. 9 , assembled circuit board 172 includes a microcontroller circuit 808 , a reverse battery protection circuit 802 , a linear regulator circuit 804 , a first mode memory device 810 , a second mode memory device 812 , a third mode memory device 814 , a bypass switch 806 , a MOSFET driver 820 , a load switch 822 , a momentary pad 289 , a latch pad 288 , and a cell count test point 824 .
Detailed electrical circuit schematics of assembled circuit board 172 are shown in FIGS. 10A-E .
FIG. 10A shows a circuit schematic diagram of reverse battery protection circuit 802 . The reverse battery protection circuit 802 takes the voltage 702 from the positive electrode of a battery of a battery pack and connects it to a source of a p-channel metal-oxide-semiconductor field-effect transistor (PMOS) 712 . The gate of PMOS 712 is connected to ground 714 while the drain of PMOS 712 is connected to an internal voltage supply 704 for assembled circuit board 172 . With this reverse battery protection circuit 802 , when the battery or battery pack is installed in reverse order, no current will be flowed through current paths of the flashlights.
Referring to FIG. 10B , microcontroller circuit 808 includes a microcontroller 720 and connections. Microcontroller 720 receives input signals through signal lines ADC_MODE_CAP 1 722 , ADC_MODE_CAP 2 724 , ADC_MODE_CAP 3 726 , MISO 730 , MOMENTARY_SWITCH 736 , MAIN_SWITCH 738 , and RESET 742 . Microcontroller 720 also delivers output signals through signal lines ADC_MODE_CAP 1 722 , ADC_MODE_CAP 2 724 , ADC_MODE_CAP 3 726 , BYPASS_LDO 734 , and LAMP_DRIVE 740 . In accordance, signal lines ADC_MODE_CAP 2 722 , ADC_MODE_CAP 1 724 , ADC_MODE_CAP 3 726 are bi-directional. In one embodiment, the microcontroller 720 is a commercial microcontroller having embedded memory, such as, for example, ATtiny24 which is an 8-bit microcontroller manufactured by Atmel Corporation of San Jose, Calif. In another embodiment, the microcontroller 720 can be a microprocessor. Yet in other embodiments, the microcontroller 720 can be discrete circuits.
Microcontroller 720 has a power supply source 708 to provide voltage input. Typically, microcontroller 720 can not accept a power supply source that is higher than a predefined value, for example, 5.5 volts. However, flashlights 100 and 300 can be adjusted to contain two, three or four batteries (depending on the length of barrel) that the battery voltage source 702 (and also 704 ) can range from 3.0 volts to 6.0 volts. If a flashlight is designed for using four batteries, voltage from the battery voltage source 702 cannot be used to supply the microcontroller 708 directly.
FIG. 10C shows a circuit schematic diagram of linear regulator circuit 804 . The linear regulator circuit 804 takes the internal voltage supply 704 from reverse battery protection circuit 802 as input voltage and convert it into an digital voltage output source 708 for supplying the microcontroller 708 through two different paths. The first path is through a low drop-out (LDO) linear voltage regulator 716 and the second path is to bypass the LDO linear voltage regulator 716 and pass through a PMOS 750 .
When flashlight 100 or 300 is designed for receiving four batteries, internal voltage supply 704 can not be used to supply microcontroller 720 directly. Signal line BYPASS_LDO 734 would be turned low by microcontroller 708 . Thus, bipolar transistor 806 with built-in resistors would not be conduct. In accordance, PMOS 750 would not be conduct. Internal voltage supply 704 would be converted to digital voltage output source 708 through LDO linear voltage regulator 716 which would provide an output voltage source that is lower than the input voltage supply. In the present embodiment, the LDO linear voltage regulator 716 would drop the input voltage for about 1.0 volt.
When flashlight 100 or 300 is designed for receiving two or three batteries, or if flashlights 400 , 600 with battery pack are used, internal voltage supply 704 could be used to supply microcontroller 720 directly. Signal line BYPASS_LDO 734 could be turned high by microcontroller 708 . In this situation, bipolar transistor 806 with built-in resistors would be conduct, and therefore, PMOS 750 would be conduct. Internal voltage supply 704 would now be converted to digital voltage output source 708 through PMOS 750 and bypass the LDO linear voltage regulator 716 .
In the embodiment of FIG. 10C , internal voltage supply 704 may be coupled to digital voltage source 708 first through a resistor 744 before passing through the LDO linear voltage regulator 716 or the PMOS 750 . Resistor 744 and capacitor 746 constitute a RC filter that filters out noises, for example, noise due to the switching of PMOS 780 (see FIG. 10D ). This RC filter helps reduce errors when microcontroller 720 is making analog-to-digital conversions. In the present embodiment, resistor 744 may be set at 18 Ohms, for example, while capacitor 746 may be set at 1.0 micro Farad, for example.
Microcontroller 720 can be programmed during manufacturing of flashlight to put the number of battery cell information through cell count test point 824 (shown in FIG. 9 ) to decide whether to turn signal line BYPASS_LDO 734 high or low. This battery cell count information is also stored in an embedded non-volatile memory, such as EEPROM, of microcontroller 720 for calculating power profile which will be described in more detail.
FIG. 10D shows a circuit schematic diagram of MOSFET driver circuit 820 and a load switch 822 . In the embodiment of FIG. 10D , load switch 822 is implemented by a PMOS 780 that the source of PMOS 780 is coupled to internal voltage supply 704 while the drain of PMOS 780 is coupled to voltage output pin 710 . Voltage output pin 710 can be coupled to the positive electrode of the LED 145 of flashlight 100 . The gate of PMOS 780 is coupled to a MOSFET driver 820 , which is implemented by a bipolar transistor 782 . The gate of PMOS 780 is also pulled-up to internal voltage supply 704 by a resistor 778 . In accordance, when the base of bipolar transistor 782 is driven high by signal LAMP_DRIVE 740 , bipolar transistor 782 is conduct and so is PMOS 780 . Therefore, electric power can flow from internal voltage supply 704 to voltage output pin 710 to form a portion of a complete loop of electric current path that can turn the LED 145 on.
In the present embodiments, as long as the batteries or battery pack is installed and the connecting parts are working, the assembled circuit board 172 is supported by power from the batteries or battery pack regardless whether the flashlight 100 is switch on or switched off. Microcontroller 720 by default is in a very low power stand-by mode to minimize drain on the batteries. When momentary pad 289 is grounded by snap dome 170 , microcontroller 720 will wake up from low power stand-by mode and turn on a load switch 780 , which turns on the LED 145 of the flashlight 100 . As long as momentary pad 289 is grounded, the LED 145 will be on full power. Once the switch button 200 is released and momentary pad 289 is no longer grounded, microcontroller 720 will turn off load switch 780 and the LED 145 will be off. Microcontroller 720 will then go back to low power stand-by mode.
If switch button 200 is pressed further that both momentary pad 289 latch pad 288 are grounded, the LED 145 will stay on until another full press is detected
Referring to FIG. 10E , the three mode memory devices 810 , 812 , 814 will now be described together. The first mode memory device 810 has an input/output signal line ADC_MODE_CAP 1 724 to be coupled to microcontroller 720 . Signal line ADC_MODE_CAP 1 724 is also coupled to one end of resistor 754 . The other end of resistor 754 is coupled to a RC circuit with resistor 756 and capacitor 758 connected in parallel. The other end or the RC circuit is coupled to ground. This first mode memory device 810 can be used to store information in a temporary manner. Microcontroller 720 can store an information in mode memory device 810 by setting signal line ADC_MODE_CAP 1 724 to a high or a low. The high information would be store in the first mode memory device 810 for a short period of time, for example, 2 seconds, before it is decayed and cannot be recognized. Microcontroller 720 can execute a read operation from signal line ADC_MODE_CAP 1 724 to retrieve data value stored in the first mode memory device 810 . In the present embodiment, the resistance of resistor 756 is 1.0 Mega Ohms while the capacitance of capacitor 758 is 1.0 micro Farad. Similarly, the second mode memory device 812 and the third mode memory device 814 can have the same configuration as that of the first mode memory device 810 .
In the present embodiments, flashlight 100 has eight modes of operation. When the flashlight is switched on, microcontroller 720 reads mode information from an internal memory, for example, an embedded SRAM built in the microcontroller 720 . Microcontroller 720 increments the mode information by one to obtain a current mode information and stores the current mode information to the external mode memory devices 810 , 812 , 814 . Flashlight 100 goes to the new mode of operation accordingly.
For example, when switch button 200 is hard pressed into latch position while flashlight 100 is in off mode, microcontroller 720 reads the previous mode information from the embedded SRAM. If the previous mode information is 0,0,0, microcontroller 720 increments it by one to obtain the current mode information, which is 0,0,1. In the present embodiment, a 0,0,1 mode information represent a full power mode. In accordance, flashlight 100 enters the full power mode. Microcontroller 720 then write the current mode information into the three mode memory devices 810 , 812 , 814 by pulling signal lines ADC_MODE_CAP 3 726 and ADC_MODE_CAP 2 722 to low and pulling signal line ADC_MODE_CAP 1 724 to high.
While the flashlight 100 is in an operation mode other than off mode, if the switch button 200 is hard pressed into latch position (both momentary pad 289 and latch pad 288 are grounded), and hold it for a period of time, for example, two seconds, in the present embodiment, microcontroller 720 interprets that as a command to change mode of operation. Microcontroller 720 reads the previous mode information from the embedded SRAM and increments it by one to obtain the current mode information. If the previous mode information is 0,0,1, for example, then the current mode information would be 0,1,0. Microcontroller 720 then writes the current mode information into the three mode memory devices 810 , 812 , 814 by pulling signal lines ADC_MODE_CAP 3 726 and ADC_MODE_CAP 1 724 to low and pulling signal line ADC_MODE_CAP 2 722 to high. In the present embodiment, this 0,1,0 combination represents a 50% power save mode.
In the present embodiment, the 0,1,1 combination stored in the three mode memory devices 810 , 812 , 814 represents that the current mode is a 25% Power Save mode. The rest of the operation modes for flashlight 100 are shown in Table 1.
TABLE 1
Operation Modes and Code
Mode Name
Current Mode
Next Mode
Off
0, 0, 0
0, 0, 1
Full Power
0, 0, 1
0, 1, 0
50% Power Save
0, 1, 0
0, 1, 1
25% Power Save
0, 1, 1
1, 0, 0
10% Power Save
1, 0, 0
1, 0, 1
Blink
1, 0, 1
1, 1, 0
Beacon
1, 1, 0
1, 1, 1
SOS
1, 1, 1
1, 1, 1
As long as the user continues to hold the switch 200 in the latch position, the flashlight 100 will make a transition through the lists of modes above. Every time a determined period of time, for example, two seconds, has passed, the mode count will be incremented.
Flashlight 100 may face a power interruption while the flashlight 100 is turned on or turned off. For example, when there is a need for battery replacement, flashlight 100 (and also the microcontroller 720 ) could experience a relatively long period of power interruption. When the flashlight is accidentally dropped on the ground or hit to a hard surface from one end of its ends, the inertia of the batteries or battery pack could cause the batteries or battery pack to disconnect from one of the battery contacts for a short period of time and that causes a short period of power interruption.
In the present embodiment, after flashlight 100 has experienced a power interruption, no matter it is a relatively long period or a short period, when the power turned back on, microcontroller 720 runs a powered up routine, which includes a read from the three mode memory devices 810 , 812 , 814 through signal lines ADC_MODE_CAP 3 726 , ADC_MODE_CAP 2 722 , ADC_MODE_CAP 1 724 . Accordingly, flashlight 100 enters the mode information indicated by the mode memory devices 810 , 812 , 814 .
For example, after a battery replacement, the mode information indicated by the mode memory devices 810 , 812 , 814 should be 0,0,0 since charges stored on capacitors 758 , 764 , 770 should have been decade. Microcontroller 720 then reads from the three mode memory devices 810 , 812 , 814 and obtains 0,0,0 as previous mode information. Accordingly, flashlight 100 enters the off mode.
On the other hand, if the flashlight is accidentally dropped on the ground or hit to a hard surface from one end of its ends, the inertia of the batteries or battery pack could cause the batteries or battery pack to disconnect from one of the battery contacts for a short period of time and that causes a short period of power interruption, typically shorter than 0.5 seconds. If the mode of operation right before the accident is, for example, the SOS mode, the charges stored on capacitors 758 , 764 , 770 are still retained as it is before the accident after the reconnection. Microcontroller 720 then reads from the three mode memory devices 810 , 812 , 814 and obtains 1,1,1 as previous mode information. Accordingly, flashlight 100 enters the SOS mode which is the operating mode before the accident. In other words, the flashlight 100 has immunity from such accident.
The power immunity from interruption of flashlight 100 also applies to the condition when the flashlight 100 is in the off mode. When the flashlight 100 is switched off, microcontroller 720 write 0,0,0 to the three mode memory devices 810 , 812 , 814 , and microcontroller 720 enters a low power stand-by mode. Therefore, regardless of a short power interruption or a long power interruption, after the power connection is restored, microcontroller 720 reads from the three mode memory devices 810 , 812 , 814 and obtains 0,0,0 as previous mode information. Accordingly, flashlight 100 enters the off mode.
The electronic switch supplies power to LED 145 at different duty cycles to maximize battery life. Microcontroller 720 including an internal memory for storing data battery count information and the power profile information for a variety of batteries that can be installed to flashlight 100 . For most of the battery life, electronic switch 822 provides full power (100% duty cycle) to LED 145 . As the batteries deplete, battery voltage 702 will drop and this is monitored by microcontroller 720 . Microcontroller 720 uses the power profile for each battery to decide when to reduce the duty cycle and when to keep.
Each battery has limited life cycle including a high voltage period, a voltage depletion period and a low voltage period. When battery voltage 702 is in the high voltage period, microcontroller 720 provides a high duty cycle signal to the lamp drive output pin 740 for MOSFET driver 820 to provide a high duty cycle power supply 710 to LED 145 . When battery voltage 702 is in the voltage depletion period, the microcontroller 720 gradually declines the duty cycle signal to the lamp drive output pin 740 for MOSFET driver 820 to provide a gradually declined power supply 710 to LED 145 . When battery voltage 702 is in the low voltage period, microcontroller 720 provides a low duty cycle signal to the lamp drive output pin 740 for MOSFET driver 820 to provide a low duty cycle power supply 710 to LED 145 . FIG. 11A is a power profile for two cell batteries. FIG. 11B is a power profile for three cell batteries. FIG. 11C is a power profile for four cell batteries. By reducing duty cycle towards the end of batteries' life, the usable time of batteries can be significantly extended.
While various embodiments of an improved flashlight and its respective components have been presented in the foregoing disclosure, numerous modifications, alterations, alternate embodiments, and alternate materials may be contemplated by those skilled in the art and may be utilized in accomplishing the various aspects of the present invention. For example, the power control circuit and short protection circuit described herein may be employed together in a flashlight or may be separately employed. Further, the short protection circuit may be used in rechargeable electronic devices other than flashlights. Thus, it is to be clearly understood that this description is made only by way of example and not as a limitation on the scope of the invention as claimed below. | A flashlight stores a user selection of a desired mode of operation in a temporary storage medium so that it can be retrieved by a controller when an electrical circuit is interrupted for less than a preselected period of time. | 7 |
CROSS REFERENCE TO RELATED APPLICATION
[0001] This application claims the benefit of priority to Korean Application No. 10-2009-0049003, filed on Jun. 3, 2009, which is hereby expressly incorporated by reference in its entirely.
FIELD
[0002] The present disclosure relates to a refrigerator.
BACKGROUND
[0003] In general, a refrigerator uses cold air produced as refrigerant vaporizes and absorbs heat from the air.
[0004] In detail, the refrigerant is compressed at a compressor, and forwarded to an evaporator via an expansion valve, where the refrigerant vaporizes. The refrigerant absorbs heat from surroundings in such a vaporizing process, and cools down surrounding air to produce the cold air.
[0005] The cold air is forwarded to the refrigerating chamber or the freezing chamber for maintaining the refrigerating chamber or the freezing chamber to be below a fixed temperature.
[0006] Depending on arrangement of the refrigerating chamber or the freezing chamber, in the refrigerators, there are a top mount-type refrigerator in which the freezing chamber is arranged on the refrigerating chamber, a bottom freezer type refrigerator in which the freezing chamber is arranged under the refrigerating chamber, and a side by side type refrigerator in which the refrigerating chamber and the freezing chamber are arranged side by side. Above categorization is just for convenience's sake, but not absolute ones.
[0007] The bottom freezer type refrigerator has an inside space partitioned with a barrier, an upper side of which is the refrigerating chamber and a lower side of which is the freezing chamber.
[0008] In general, the refrigerating chamber has at least one refrigerating chamber door rotatably mounted thereto to open/close the refrigerating chamber, and the freezing chamber has a drawer structure which is slidably moved back and forth to open/close the freezing chamber.
[0009] In general, in rear of the freezing chamber and the refrigerating chamber, there are the evaporators and fans for blowing the cold air respectively, for generating the cold air individually to control temperatures of the freezing chamber and the refrigerating chamber, respectively.
SUMMARY
[0010] In one aspect, a refrigerator includes a cold air generator configured to generate cold air. The refrigerator also includes a storage chamber configured to receive the cold air generated by the cold air generator, and store at least one food and ice stuffs. The refrigerator further includes a storage chamber door configured to open and close an access point to the storage chamber. In addition, the refrigerator includes an inner frame coupled to the storage chamber and configured to move at least a part of the storage chamber in forward and backward directions.
[0011] Implementations may include one or more of the following features. For example, the refrigerator further includes a drawing out device configured to move the inner frame in connection with opening and closing of the door. The drawing out device includes a link device connected to the door and the inner frame. The link device includes a first link connected to the inner frame and a second link connected to the door. The inner frame includes an upper surface positioned at upper side from a center of the refrigerator and slidably connected to a top wall surface of the storage chamber and a lower surface positioned at lower side from the center of the refrigerator and slidably connected to a bottom wall surface of the storage chamber.
[0012] In some examples, the inner frame includes a top sliding unit slidably connected to a ceiling surface of the storage chamber and a bottom sliding unit slidably connected to a bottom surface of the storage chamber. The at least a part of the storage chamber comprises the plurality of shelves and/or drawers that are mounted in the inner frame. The storage chamber includes at least one of a refrigerating chamber and a freezing chamber. The refrigerator further includes a protector configured to prevent the refrigerator from falling down when the inner frame moves in the forward and backward directions.
[0013] In another aspect, a refrigerator includes a cold air generator configured to generate cold air. The refrigerator also includes a storage chamber having a moving member, configured to receive the cold air generated by the cold air generator, and store at least one food and ice stuffs. The refrigerator further includes a door configured to open and close the storage chamber, wherein the moving member is configured to be moved in forward and backward directions in response to opening and closing of the door.
[0014] Implementations may include one or more of the following features. For example, the moving member includes an inner frame configured to be slidably moved in the forward and backward directions and a moving structure mounted in the inner frame, and configured to be moved together with the inner frame. The moving structure includes at least one a shelf and a drawer. The refrigerator further includes a drawing out device configured to move the moving member responsive to opening and closing of the door. The drawing out device includes a link device connected to the door and the inner frame.
[0015] In some examples, the storage chamber includes at least one of a refrigerating chamber and a freezing chamber. The refrigerator further includes a protector configured to prevent the refrigerator from falling down when the moving member moves in the forward and backward directions. The refrigerator further includes a motor configured to provide a driving force to the moving member to move the moving member in response to opening and closing of the door.
[0016] In yet another aspect, a refrigerator includes a cold air generator configured to generate cold air. The refrigerator also includes a storage chamber having a first moving member and a second moving member, configured to receive the cold air generated by the cold air generator, and store at least one food and ice stuffs. The refrigerator further includes a first door configured to open and close at least a part of the storage chamber, wherein the first moving member is configured to be moved in forward and backward directions in response to opening and closing of the first door. In addition, the refrigerator includes a second door configured to open and close at least a part of the storage chamber, wherein the second moving member is configured to be moved in forward and backward directions in response to opening and closing of the second door.
[0017] Implementations may include one or more of the following features. For example, the first moving member includes a first inner frame configured to be slidably moved in the forward and backward directions and a first moving structure positioned in the first inner frame, and configured to be moved together with the first inner frame. The second moving member includes a second inner frame configured to be slidably moved in the forward and backward directions and a second moving structure positioned in the second inner frame, and configured to be moved together with the second inner frame.
[0018] The second moving member is a part of the first moving member. The first door is a refrigerator chamber door and the second door is at least one of a home bar door and a basket door. The first door is a refrigerator chamber door and the second door is a freezing chamber door.
[0019] In some examples, the first and the second door are independently opened and closed. The storage chamber comprises at least one of a refrigerating chamber and a freezing chamber. The refrigerator further includes a third door configured to open and close at least a part of the storage chamber and a third moving member configured to be moved in forward and backward directions in response to opening and closing of the third door.
BRIEF DESCRIPTION OF THE DRAWINGS
[0020] FIG. 1 illustrates a view of a refrigerator when a refrigerating chamber and a freezing chamber are opened;
[0021] FIG. 2 illustrates an exploded perspective view of an inner frame, shelves and drawers mounted therein;
[0022] FIG. 3 illustrates a perspective view showing a state in which a refrigerating chamber door and an inner frame are connected with a link device in a door closed state; and
[0023] FIGS. 4 and 5 illustrate perspective views of sliding structures of the inner frames, respectively.
DETAILED DESCRIPTION
[0024] Reference will now be made in detail to the specific implementations of the present technology, examples of which are illustrated in the accompanying drawings FIGS. 1 to 5 . Wherever possible, the same reference numbers will be used throughout the drawings to refer to the same or like parts.
[0025] A refrigerator shown in FIG. 1 is a side by side door type refrigerator, wherein a freezing chamber 10 is on a left side and a refrigerating chamber 20 is on a right side.
[0026] The refrigerating chamber 20 and the freezing chamber 10 are opened/closed by a refrigerating chamber door 21 and a freezing chamber door 11 , respectively. In inside walls of the refrigerating chamber door 21 and the freezing chamber door 11 , there are shelves and so on for storage, respectively. And, there are an ice maker mounted to the freezing chamber door 11 and a home bar mounted to the refrigerating chamber door 21 .
[0027] Mounted in spaces of the refrigerating chamber and the freezing chamber 10 , there are storage structures 30 and 40 , respectively. The storage structures and 40 are mounted to be movable in front/rear directions in the refrigerating chamber 20 and the freezing chamber 10 .
[0028] Since it is required to secure spaces for placing the ice maker or the home bar therein at the time the refrigerating chamber door 21 and the freezing chamber door 11 are closing, front/rear direction depths of the storage structures 30 and 40 can be determined, taking the spaces to be secured into account.
[0029] Each of the storage spaces 30 and 40 includes an inner frame 43 and a plurality of shelves and drawers arranged vertically in the inner frame 43 , as shown in FIG. 2 . FIG. 1 illustrates a perspective view showing the storage structures 30 and 40 moved forward.
[0030] The storage structure will be described in detail with reference to the storage structure 40 mounted in the refrigerating chamber 20 .
[0031] Referring to FIG. 2 , the inner frame 43 includes one pair of vertical supporting frames 44 , a top frame 45 extended from a top edge of the supporting frames 44 perpendicular thereto, and a bottom frame 46 extended from a bottom edge of the supporting frames 44 perpendicular thereto.
[0032] There are a plurality of shelves 41 arranged in a vertical direction in the one pair of the supporting frames 44 , and a drawer unit 42 having a plurality of drawers provided therein under the shelves 41 .
[0033] As a variation, a plurality of drawers can be provided and mounted to the inner frame 43 , individually.
[0034] The inner frame 43 is housed in the refrigerating chamber 20 . Though the inner frame 43 has a height as high as the refrigerating chamber 20 , as a variation, the inner frame 43 can be fabricated to have a height lower than the refrigerating chamber 20 . That is, the inner frame 43 can be fabricated to have a height to occupy a portion of the refrigerating chamber 20 space, such as an upper space thereof or a lower space thereof.
[0035] Referring to FIG. 4 , the inner frame 43 is mounted to be slidable along wall surfaces of the refrigerating chamber 20 in front/rear directions.
[0036] FIGS. 4 and 5 illustrate perspective views each showing the inner frame 43 mounted such that a top surface and a bottom surface of the inner frame 43 are slidable with respect to a ceiling surface and a bottom surface of the refrigerating chamber 20 , respectively.
[0037] In detail, the refrigerating chamber 20 has a top sliding guide 72 mounted to the ceiling surface thereof and the inner frame 43 has a top slider 71 mounted to the top surface thereof slidably connected to the top sliding guide 72 . The top slider 71 and the top frame 45 of the inner frame 43 together form a top sliding unit.
[0038] The refrigerating chamber 20 has a bottom slider 82 mounted on a bottom surface, and to match with this, the inner frame 43 has a bottom slider 81 mounted to a bottom surface of the inner frame 43 . The bottom slider 81 and the bottom frame 46 together form a bottom sliding unit.
[0039] Owing to above sliding structure, the inner frame 43 can slide in the refrigerating chamber 20 in front/rear directions.
[0040] In the meantime, there are link devices 60 and 65 mounted to the refrigerator for making the inner frame 43 to be movable in front/rear directions interlocked to the opening/closing of the refrigerating chamber door 21 .
[0041] The link device includes a first link 61 or 66 rotatably connected to the inner frame 43 , and a second link 62 or 67 rotatably connected to the refrigerating chamber door 21 .
[0042] The link devices 60 and 65 are mounted to a top and a bottom respectively, wherein the top first link 61 and the top second link 62 are mounted to the top, and the bottom first link 66 and the bottom second link 67 are mounted to the bottom.
[0043] There can be another means for interlocking the opening/closing of the refrigerating door 21 with the sliding of the inner frame 43 . For an example, a rack gear can be provided to the inner frame 43 , and a motor can be connected to the rack gear through a gear. Accordingly, the motor is made to operate as the door 21 opens, to make the inner frame 43 to slide forward.
[0044] In a state the refrigerating door 21 is closed, the refrigerator has the inner frame 43 positioned on a rear side of the refrigerating chamber 20 , and the home bar and the shelves mounted in the inside wall of the refrigerating chamber door 21 positioned in a front side space of the refrigerating chamber 20 . FIG. 3 illustrates a perspective view showing arrangement of the inner frame 43 and the refrigerating chamber door 21 in a state the refrigerating chamber door 21 is closed.
[0045] In this state, if the refrigerating chamber door 21 is opened, the inner frame 43 slides forward interlocked with the opening of the refrigerating chamber door 21 . FIG. 1 illustrates a perspective view showing a state the inner frame 43 is drawn out to a front side in a state the refrigerating chamber door 21 is opened, fully.
[0046] In some examples, the inner frame is moved in forward and backward directions in connection with opening and closing the refrigerating chamber door 21 . In the opening operation, after the refrigerating chamber door 21 is opened to open the refrigerating chamber 20 or while the refrigerating chamber door 21 is being opened, the motor provides a driving force to the rack gear to move the closing motor in the forward or front direction. In the closing state, before the refrigerating chamber door 21 is closed to close the refrigerating chamber 20 or while the refrigerating chamber door 21 is being closed, the motor provides a driving force to the rack gear to move the inner frame in the backward or rear direction.
[0047] In some examples, configuration of the inner frame 43 can be modified. For example, a plurality of the inner frames could be mounted in the refrigerating chamber 20 . If the refrigerator has two inner frames, as an example, an upper inner frame may have a height that corresponds to that of the home bar, and a lower inner frame may have a height that corresponds to that of the baskets location. That is, as shown in FIG. 3 , the refrigerating chamber door 21 may divide two doors, which are a home bar door 22 and a basket door 23 . In this implementation, a user may independently open and close the home bar door 22 and the basket door 23 . When the user opens the home bar door 22 , the upper inner frame and a corresponded structure (e.g., a plurality of shelves or draws) that is mounted in the upper inner frame move in the forward direction of the refrigerator, and when the user closes the home bar door 22 , the upper inner frame and the corresponded structure move in the backward direction of the refrigerator. Likewise, when the user opens the bracket door 23 , the lower inner frame and a corresponded structure that is coupled to the bracket door move in the forward direction of the refrigerator, and when the user closes the bracket door 23 , the lower inner frame and the corresponded structure move in the backward direction of the refrigerator.
[0048] Further, in the above implementation, when the user opens the refrigerating chamber door 21 , the inner frame 43 and the corresponded structure 40 as shown in FIGS. 4 and 5 move in the forward direction of the refrigerator, and when the user closes the refrigerating chamber door 21 , the inner frame 43 and the corresponded structure move 40 in the backward direction of the refrigerator. In this case, the home bar door 22 and the basket door 23 may be a part of the refrigerating chamber door 21 . Also, moving structure or structure in connection with the home bar door 22 may be a part of the moving structure 40 . Further, moving structure in connection with the basket door 23 may be a part of the moving structure 40 .
[0049] As a moving structure (i.e., a part of storage chamber) may be moved in connection with movement of a door, various modifications are possible. For example, two moving members are moved in connection with opening and closing the refrigerating chamber door 21 and the home bar door 22 , respectively. Alternatively, two moving members are moved in connection with opening and closing opening and closing the refrigerating chamber door 21 and the basket door 23 , respectively. The moving members may include the inner frame and corresponded structure or components.
[0050] As an example, the home bar door 22 is a part of the refrigerating chamber door 21 . So, the moving member moved in connection with the home bar door may be a part of the moving member moved in connection with the refrigerating chamber door 21 .
[0051] It is also available that a plurality of moving members in a refrigerators that are independently moved in connection with opening and closing of three or more than three doors.
[0052] Since moving member or members are moved in the forward and backward directions, the refrigerator may need a protector to prevent the refrigerator from falling down. For example, when the moving structure 40 moves in the forward direction of the refrigerator, a lot of stuffs contained in the storage chamber also move in the forward direction. Therefore, it may cause to fall the refrigerator down because a relatively heavy weight was shifted to the front or forward side within a short period. To avoid falling down, the refrigerator may keep contacting or connecting an adjacent thing, such as a wall, when the moving structure 30 or 40 moves in the forward direction. In this implementation, an end of protector (e.g., a string) is connected to the refrigerator and the other end of the protector is connected to the wall such that the refrigerator can't be moved away from the wall.
[0053] As has been described, since the storage structure mounted in the storage chamber can be movable in front/rear directions, drawing out/pushing in of a storage object becomes more convenient.
[0054] It will be understood that various modifications may be made without departing from the spirit and scope of the claims. For example, advantageous results still could be achieved if steps of the disclosed techniques were performed in a different order and/or if components in the disclosed systems were combined in a different manner and/or replaced or supplemented by other components. Accordingly, other implementations are within the scope of the following claims. | A refrigerator includes a cold air generator configured to generate cold air. The refrigerator also includes a storage chamber configured to receive the cold air generated by the cold air generator, and store at least one food and ice stuffs. Further, the refrigerator includes a storage chamber door configured to open and close an access point to the storage chamber. In addition, the refrigerator includes an inner frame coupled to the storage chamber and configured to move at least a part of the storage chamber in forward and backward directions. | 5 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to pistons for internal combustion engines, pumps, compressors and other applications and particularly to cast or forged pistons having oil passages formed at least in part during molding.
2. Description of the Prior Developments
Pistons for use in internal combustion engines and other applications typically are formed with one or more circumferential grooves for receiving one or more piston rings. The grooves are generally formed by a separate machining operation after the piston has been cast or forged. In the case of the oil ring groove, additional machining is typically needed after the groove is formed in order to form drain holes which allow oil to flow through the piston groove to return to an oil sump.
In some cases, cast or forged pistons are subjected to additional machining in order to reduce the weight of the piston. Recesses or bores are machined in the piston, generally in the floor of the piston to remove material and reduce weight.
Although these prior pistons perform adequately, the additional drilling and boring of the oil drain holes adds to the cost of manufacture.
Accordingly, a need exists for a piston having oil drain holes formed in an oil ring groove in such a manner that supplemental machining such as drilling and boring is obviated.
SUMMARY OF THE INVENTION
The present invention has been developed to meet the needs noted above and therefore has as an object the provision of a piston having drain holes formed in an oil ring groove without drilling or boring.
Another object of the invention is the provision of such a piston which is particularly well suited to fabrication by semi-solid molding techniques as well as more conventional technologies such as gravity casting or forging.
Another object of the invention is to form, by casting or forging, recesses or undercuts in the floor or underside of a piston so as to reduce the weight of the piston.
These and other objects are met by the present invention which is directed to a piston having one or more recesses or undercuts formed in the bottom portion of the piston body. Each undercut or recess is positioned to extend upwardly to a point which intersects the location of a later formed oil ring groove which is subsequently machined around the circumference of the piston wall.
Accordingly, when the oil ring groove is radially cut into the circumference of the piston wall, an opening or flow passage is formed from the ring groove to the interior of the piston via the undercut. In this manner, oil collected by the oil ring can circulate freely in accordance with common practice.
These and other objects, features and advantages of the invention will become more apparent as the following description proceeds, especially when considered with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
In the drawings:
FIG. 1 is a front elevation view of a piston constructed in accordance with the invention;
FIG. 2 is a side elevation view of FIG. 1;
FIG. 3 is a bottom view of FIG. 1;
FIG. 4 is a view of a piston similar to that of FIG. 2 before the grooves are machined around the outer wall of the piston, and showing a piston groove and drain port recesses in dashed lines;
FIG. 5 is a top plan view, in fragment, of an oil groove and drain port formed in the piston of FIG. 4;
FIG. 6 is a view similar to FIG. 4 showing another embodiment of the invention; and
FIG. 7 is a view, in fragment, taken along line 7--7 of FIG. 6.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
The present invention will now be described in conjunction with the drawings, beginning with FIGS. 1, 2 and 3 which show, by way of example, a piston 10 of the type used in internal combustion engines. Piston 10 includes an upper cylindrical head portion 12 and a lower skirt portion 14.
The head portion 12 is formed with one or more circumferential grooves such as a pair of compression ring grooves 16 and an oil ring groove 18. Grooves 16 and 18 are typically formed by a turning operation such as a lathe cutting operation, after the head and skirt are formed. A pair of radially recessed or undercut arcuate reliefs 19 is formed beneath the head portion 12 so as to define a pair of somewhat C-shaped overhanging floor or ledge portions 21.
As seen in FIGS. 2 and 3, a pair of U-shaped wrist pin bosses 22 is formed adjacent ledges 21. The bosses extend downwardly from the underside or bottom surface 24 of the head portion 12. Each arched boss 22 is formed with a cylindrical bore 26 for receiving and supporting a common wrist pin.
Four curved (or optionally straight) axially-extending flanges or window walls 28 formed on the floor or bottom surface 24 interconnect the wrist pin bosses 22 with the skirts 14 to control elastic deformation of the skirts 14 caused by mechanical side forces.
At least one axially extending recess, relief, undercut or depression is formed in bottom surface 24 adjacent at least one of the grooves 16, 18. As seen in the examples of FIGS. 2 and 3, four symmetrically-spaced somewhat dome-shaped recesses 32 are formed in surface 24 and within ledges 21 on opposite ends of each boss 22, next to each window wall 28. The recesses 32 are preferably formed during the initial forming of piston 10. Piston 10 and recesses 32 can be formed by casting, molding, forging or semi-solid molding using, for example, aluminum alloy materials.
Due to the specific geometry and short axial length of the piston 10, relatively little alloy is used to form the piston. In this case, semi-solid molding is particularly effective in forming the piston using a heated billet which is molded in a semi-solid or highly viscous and easily deformable state.
The depth and location of each recess 32 is selected to intersect one or more of the grooves when and where the grooves are later formed. In this example, each recess 32 extends axially upwardly into the head portion 12 to a point coextensive with oil groove 18. When groove 18 is later cut into the cylindrical sidewall 34 of head portion 12, a portion of each recess is truncated, cut away or severed. This cutting, by lathe or other turning operation, creates an opening in the form of a drain port 36 which is formed in the floor 38 of oil groove 18 by the innermost tip or inner portion of each recess 32. Of course, other portions of recess 32 could be truncated or severed such as the sidewall of each recess 32.
In this manner, four drain ports 36 are formed in the radially-extending annular floor 38 of oil groove 18 to allow oil to flow through each drain port to an oil sump. This particular piston structure and forming method obviates the need for a separate drilling operation typically required to form oil return drain ports commonly referred to as "smoke holes". Drain ports 36 and recesses 32 also reduce the weight of the piston.
It should be noted that the lower annular or cylindrical circumferential wall or flange 40, also called the "fourth land", which extends downwardly toward the skirt portion 14 from groove 18 is continuous and unbroken so that wall 40 provides a 360° circumferential support to piston 10. The continuous and unbroken fourth land 40 also provides an uninterrupted cut of the ring land area 12 during machining, which improves the machinability of the piston. This structure should be contrasted with prior piston designs which provided for oil drainage from groove 18 by forming grooves, breaks, or cuts through the outer curved surface of wall 40 and/or skirt portion 14. This approach did not provide a continuous, unbroken 360° wall around the floor of groove 18 as does the present invention.
The relative positioning of the recesses 32 and oil ring groove 18 are shown in their as-cast condition in FIG. 4, before the oil groove 18 is cut and turned by a lathe. After turning, the drain port 36 is shown in FIG. 5 as a round hole formed through floor 38 of groove 18. Of course, any other shaped hole may be formed, depending on the shape of recesses 32 which can be formed with virtually any desired shape.
If desired, drain port 36 may also be formed in the radially-inner axially-extending wall 44 of groove 18, commonly known as the "groove root". This simply requires a corresponding alignment of recess 32 with groove 18 as shown in FIGS. 6 and 7 wherein the sidewall of recess 32 is truncated or cut away by groove 18.
It should be understood that while this invention has been discussed in connection with one particular example, those skilled in the art will appreciate that other modifications can be made without departing from the spirit of this invention after studying the specification, drawings, and the following claims. | A piston is formed with one or more recesses or depressions on its underside as it is cast, molded or forged. The recesses are located adjacent the outer cylindrical wall of the piston head so that when a groove such as an oil ring groove is subsequently machined into the outer wall, the groove intersects and cuts into each recess. In this manner, oil drain ports are formed in the oil ring groove without the need for additional boring or cutting operations. | 5 |
The present application claims the benefit of U.S. Provisional Application Ser. No. 60/550,904, filed Mar. 8, 2004, which application is incorporated herein by reference.
BACKGROUND OF THE INVENTION
The present invention relates to spa covers, and in particular to assembleable spa covers comprising a plurality of molded foam sections.
Spas are commonly owned and used to obtain the relaxing benefit of heated circulating water. Spa temperatures may be as high as one hundred degrees Fahrenheit. Either heating a spa to such temperatures, or maintaining such temperatures, may require a substantial use of power. Various spa covers have been devised to retain heat in spas, thereby saving power, and maintain temperatures suitable for use without extensive delays. Unfortunately, due to the size of known spas, a single piece cover is generally to large and heavy for easy manipulation.
U.S. Pat. No. 4,422,192 for “Spa or Hot Tub Cover,” describes an insulative cover which folds along a center line to reduce size and improve handling characteristic. The '192 cover comprises a vinyl cover over a foam core. The cover of the '192 patent still must be handled as a single unit and is of a size suitable for a typical spa, and therefore is quite heavy.
U.S. Pat. No. 5,685,031 for “Three-Piece Portable Spa Cover,” describes a cover which separates into two or more sections. The sections span across the spa, and are joined by “hinge-like” structure. The sections are made from molded plastic and filled with foam beads. Unfortunately, because the cover sections span across the spa, they are large and cumbersome to handle.
BRIEF SUMMARY OF THE INVENTION
The present invention addresses the above and other needs by providing a spa cover assembled from two or more molded foam sections. The sections may be molded from polystyrene, polyethylene, or a mixture of polystyrene and polyethylene. Panels are molded into the sections along mating edges, which panels cooperate to align the sections. The sections further include latches for retaining the sections in aligned cooperation. The sections taper from a peak at the center of the cover to facilitate the run-off of rain, water sprays, or spills. Holds or inserts may be molded into the foam to facilitate the use of child safety straps to secure the cover to a spa. The cover may be sized to match known spa sizes, and may include a molded in decorative pattern and/or color.
In accordance with one aspect of the invention, there is provided a spa cover comprising at least two sections. Each section comprises a molded foam body, molded-in panels for aligning adjacent sections, and latches for holding the sections in alignment. The foam may be polystyrene, polyethylene, or a mixture of polystyrene and polyethylene. The panels comprise male panels and female panels, and each section may include one of each gender of guide. The sections are preferably functionally interchangeable.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWING
The above and other aspects, features and advantages of the present invention will be more apparent from the following more particular description thereof, presented in conjunction with the following drawings wherein:
FIG. 1A is a spa with a four section spa cover according to the present invention resting on top of the spa.
FIG. 1B shows the spa cover separated into four sections.
FIG. 2A is a top view of the spa cover showing knobs for engaging latches.
FIG. 2B is a side view of the spa cover showing the knobs for engaging the latches.
FIG. 3 is a cross-sectional view of the spa cover taken along line 3 - 3 of FIG. 2B .
FIG. 3A is a more detailed cross-sectional view of one panel of the spa cover taken along line 3 - 3 of FIG. 2B .
FIG. 4A is a top view of a female panel molded into the sections of the spa cover to align the sections when the spa cover is assembled.
FIG. 4B is a front view of the female panel molded into the sections of the spa cover to align the sections when the spa cover is assembled.
FIG. 4C is a bottom view of the female panel molded into the sections of the spa cover to align the sections when the spa cover is assembled.
FIG. 5 is a cross-sectional view of the female panel taken along line 5 - 5 of FIG. 4A .
FIG. 6A is a top view of a male panel molded into the sections of the spa cover to align the sections when the spa cover is assembled.
FIG. 6B is a front view of the male panel molded into the sections of the spa cover to align the sections when the spa cover is assembled.
FIG. 7A is a cross-sectional view of the male panel taken along line 7 A- 7 A of FIG. 6A .
FIG. 7B is a cross-sectional view of the male panel taken along line 7 B- 7 B of FIG. 6A .
FIG. 8 is a perspective view depicting the cooperation of the male panel with the female panel.
FIG. 9 is a perspective view of the knob for engaging latches.
FIG. 9A is a top view of the knob for engaging latches.
FIG. 9B is a side view of the knob for engaging latches.
FIG. 10 is a cross-sectional view of the knob taken along line 10 - 10 of FIG. 9A .
FIG. 11 is a perspective view of a collar for knob.
FIG. 11A is a top view of the collar for knob.
FIG. 12 is a cross-sectional view of the collar taken along line 12 - 12 of FIG. 11A .
FIG. 13 is a perspective view of a second knob for engaging latches.
FIG. 13A is a top view of the second knob for engaging latches.
FIG. 13B is a side view of the second knob for engaging latches.
FIG. 14 is a cross-sectional view of the second knob taken along line 10 - 10 of FIG. 13A .
FIG. 15 is a perspective view of a long knob.
FIG. 15A is a side view of the long knob.
FIG. 16 is a perspective view of a long second knob.
FIG. 16A is a side view of the long second knob.
FIG. 17A is an embodiment of the present invention with four triangular sections.
FIG. 17B is an embodiment of the present invention with four pie slice shaped sections.
FIG. 17C is an embodiment of the present invention with four rectangular sections.
FIG. 17D is an embodiment of the present invention with three rectangular sections.
Corresponding reference characters indicate corresponding components throughout the several views of the drawings.
DETAILED DESCRIPTION OF THE INVENTION
The following description is of the best mode presently contemplated for carrying out the invention. This description is not to be taken in a limiting sense, but is made merely for the purpose of describing one or more preferred embodiments of the invention. The scope of the invention should be determined with reference to the claims.
A spa 12 with four rectangular sections 14 including four corners 10 ′ of a spa cover 10 according to the present invention resting on top of the spa 12 during a period of non-use is shown in FIG. lA. The spa cover 10 may be separated at mating (or engaging) edges 15 into four sections 14 as shown in FIG. 1B for easy handling. The sections 14 are preferable functionally interchangeable. The spa cover 10 is preferably molded from foam which is polystyrene, polyethylene, or a mixture of polystyrene and polyethylene, and more preferably molded from between approximately fifty percent and approximately eighty percent polystyrene and the remainder substantially polyethylene. A preferred material is ARCEL® manufactured by NOVA Chemicals in Alberta, Canada. ARCEL® is a trademark for a moldable copolymer (polystyrene and polyethylene) foam.
A more detailed top view of the spa cover 10 is shown in FIG. 2A , and a side (or edge) view of the spa cover 10 is shown in FIG. 2B . Knobs 16 visible on a top surface 10 a of the spa cover 10 are provided for actuating latches which hold the sections 14 in alignment. The sections 14 are preferably tapered from a thick inside edge (or point) 15 a to a thin outside edge 15 b to facilitate runoff.
A cross-sectional view of the spa cover 10 taken along line 3 - 3 of FIG. 2B is shown in FIG. 3 . Male panels 20 are shown in cooperation with female panels 22 to align the sections 14 . The panels 20 and 22 preferably extend between 60 percent and 90 percent of the length of the mating edges 15 of the sections 14 , and more preferably extend between approximately 71 percent and approximately 83 percent of the length of the mating edges 15 . Pairs of the knobs 16 cooperate with both the male and female panels 20 and 22 to hold the sections 14 in alignment. Tie downs (or inserts) 18 may be molded into the sections 14 to facilitate the use of child safety straps to secure the spa cover 10 to the spa 12 .
A more detailed cross-sectional view of one section 14 of the spa cover 10 taken along line 3 - 3 of FIG. 2B is shown in FIG. 3A . The sections 14 are preferably interchangeable, and it not completely interchangeable, are preferably semi interchangeable (i.e., at least two of a multiplicity of panels making up the spa cover are interchangeable). Each section 14 includes one male panel 20 and one female panel 22 on consecutive edges. The male panel 20 has a male engaging edge 15 m and the female panel had a female engaging edge 15 f.
A top view showing a horizontal outline of a female panel 22 molded into the sections 14 of the spa cover 10 to align the sections 14 when the spa cover 10 is assembled is shown in FIG. 4A , a front view showing a vertical outline of the female panel 22 is shown in FIG. 4B , and a bottom view of the female panel 22 is shown in FIG. 4G . The female panel 22 includes molded-in portions 26 which cooperate with a foam molding to fix the female panel 22 to the sections 14 . The molded-in portions 26 are preferably triangular with a passage though the center to allow the foam material to better grasp the female panels 22 . The female panels 22 also include triangular receiving portions 30 having a triangular horizontal cross-section and a rectangular vertical cross section which cooperate with triangular projecting portions 28 having a triangular horizontal cross-section and a rectangular vertical cross-section (see FIGS. 6A , 6 B, 7 A, 7 B, and 8 ) of the male panels 20 (see FIG. 6 a ) to align the sections 14 . Knobs 16 a and 16 b reside above slots (or mouths) 35 . The receiving portions 30 are preferably approximately one inch high and approximately two inches wide. Tongues 33 (see FIG. 6A ) enter the slots 35 as part of the latching of the present invention. The tongues 33 are preferably triangular and subtend an angle 31 of approximately 90 degrees.
A cross-sectional view of the female panel 22 taken along line 5 - 5 of FIG. 4A is shown in FIG. 5 . The knob 16 b resides in a collar 40 . A male latch feature 34 extends downward from the knob 16 b . The knob 16 b may be advanced into the collar 40 (and thus into the tongue 33 ) to engage a female latch feature 32 in the tongue 33 (see FIG. 6A ) to latch the sections 14 together, and to thereby hold the sections 14 in alignment. The male latch feature 34 is preferably a tapered post or a cylindrical post having a tapered end.
A top view showing a horizontal outline of a male panel 20 molded into the sections 14 of the spa cover 10 to align the sections 14 when the spa cover 10 is assembled, is shown in FIG. 6A and a front view showing a vertical outline of the male panel 20 is shown in FIG. 6B . The male panel 20 includes male molded-in portions 24 which cooperate with a foam molding to fix the male panel 20 to the sections 14 . The molded-in portions 24 are preferably rectangular with a passage though the center to allow the foam material to better grasp the male panels 20 . The male panels 20 further include projecting portions 28 having a triangular horizontal outline for cooperating with the receiving portions 30 (see FIG. 4A ), and triangular tongues 33 for engaging the slots 35 (see FIG. 4A , 4 B). The tongues 33 include female latch features 32 which are engaged by male latch features 34 (see FIG. 5 ) to hold the sections 14 in alignment.
A cross-sectional view showing a vertical outline of the male panel 20 taken along line 7 A- 7 A of FIG. 6A is shown in FIG. 7A , and a cross-sectional view of the male panel 20 taken along line 7 B- 7 B of FIG. 6A is shown in FIG. 7B . The female latch feature 32 is preferably a beveled passage through the tongue 33 . The projecting portions 28 and the molded in portions 24 preferably have a rectangular side-view (or vertical) cross-section, and are hollow with a horizontal center plates 28 a and 24 a respectively having an open center.
A detailed perspective view depicting the cooperation of the male panel 20 with the female panel 22 is shown in FIG. 8 .
A perspective view of the knob 16 a for engaging latches is shown in FIG. 9 , a top view of the knob 16 a is shown in FIG. 9A , and a side view of the knob 16 a is shown in FIG. 9B . The knob includes threads 38 a for cooperating with internal threads 38 b (see FIG. 12 ) in the collars 40 .
A cross-sectional view of the knob 16 a taken along line 10 - 10 of FIG. 9A is shown in FIG. 10 . The knob 16 a includes the male latching feature 34 preferably having a cylindrical body and a tapered end 34 a for engaging the female latching feature 32 (see FIG. 6A ).
A perspective view of the collar 40 for cooperation with the knob 16 a is shown in FIG. 11 and a top view of the collar 40 is shown in FIG. 11A . A cross-sectional view of the collar 40 taken along line 12 - 12 of FIG. 11A is shown in FIG. 12 . The collar 40 includes internal threads 38 b which cooperate with threads 38 a on the knob 16 a.
A perspective view of a second knob 17 a for engaging latches is shown in FIG. 13 , a top view of the knob 17 a is shown in FIG. 13A , and a side view of the knob 17 b is shown in FIG. 13B . The knob 17 b is pressed downward to latch and unlatch the sections 14 . A cross-sectional view of the knob 17 a taken along line 10 - 10 of FIG. 13A is shown in FIG. 14 , showing the male latching feature 34 .
A perspective view of a long knob 16 b is shown in FIG. 15 and a side view of the long knob 16 b is shown in FIG. 15A . The knob 16 b is functionally equivalent to the knob 16 a , with the exception that the knob 16 b is used at a thicker portion of the section 14 , and is therefore taller than the knob 16 a (see FIGS. 9 , 9 A, 9 B, and 10 ).
A perspective view of a long second knob 17 b is shown in FIG. 16 , and a side view of the long second knob 17 b is shown in FIG. 16A . The long knob 17 b is similarly used at a thicker portion of the section 14 and is similarly taller than the knob 17 a (see FIGS. 13 , 13 A, 13 B, and 14 ).
Various other shaped spa covers may be manufactured according to the present invention, and are intended to come within the scope of the present invention. For example, second embodiment of the present invention with four triangular sections as shown in FIG. 17A , a third embodiment of the present invention with four pie slice shaped sections as shown in FIG. 17B , a fourth embodiment of the present invention with four rectangular sections as shown in FIG. 17C , and fifth embodiment of the present invention with three rectangular sections as shown in FIG. 17D .
While the invention herein disclosed has been described by means of specific embodiments and applications thereof, numerous modifications and variations could be made thereto by those skilled in the art without departing from the scope of the invention set forth in the claims. | A spa cover is assembled from two or more molded foam sections. The sections may be molded from polystyrene, polyethylene, or a mixture of polystyrene and polyethylene. Panels are molded into the sections along mating edges, which panels cooperate to align the sections. The sections further include latches for holding the sections in alignment. The sections taper from a peak at the center of the cover to facilitate the run-off of rain, water sprays, or spills. Tie downs or inserts may be molded into the foam to facilitate the use of child safety straps to secure the cover to a spa. The cover may be sized to match known spa sizes, and may include a molded in decorative pattern and/or color. | 4 |
FIELD OF THE INVENTION
[0001] The present invention relates to a display device that includes a display panel and a neck having a rotating apparatus, such that the display panel is rotatable in a predetermined plane.
GENERAL BACKGROUND
[0002] Referring to FIG. 12 , a typical display device 4 includes a display panel 42 , a neck 44 , and a base 46 . The neck 44 is integrally formed with the base 46 , and is connected with the display panel 42 by a pivot axis 48 . The display panel 42 and the neck 44 are supported by the base 46 , and can be rotated around the pivot axis 48 .
[0003] It is widely held that a healthy position for a user to view a screen of the display panel 42 is such that a horizontal centerline of the display panel 42 is slightly below a horizontal line of sight of the user. However, the display device 4 is not configured to be readily adjustable to achieve this desired position. It can be troublesome and time-consuming for the user to try to adjust a working height of the display panel 42 of the display device 4 . Further, the display panel 42 cannot be rotated in a plane substantially perpendicular to the base 46 .
[0004] What is needed, therefore, is a display device that can overcome the above-described deficiencies.
SUMMARY
[0005] In an exemplary embodiment, an exemplary display device includes a display panel and a rotating apparatus. The rotating apparatus includes a first spindle assembly, a conveyor connecting to the first spindle assembly, and a second spindle assembly. The first spindle assembly includes a first spindle configured to synchronously rotate with rotation of the display panel. The second spindle assembly includes a second spindle meshed with the first spindle, and is configured to be able to rotate and simultaneously rise or fall along the connecting assembly.
[0006] Other novel features, advantages and aspects will become more apparent from the following detailed description when taken in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0007] The components in the drawings are not necessarily drawn to scale, the emphasis instead being placed upon clearly illustrating the principles of at least one embodiment of the present invention. In the drawings, like reference numerals designate corresponding parts throughout various views, and all the views are schematic.
[0008] FIG. 1 is an isometric view of a display device according to an exemplary embodiment of the present invention, the display device including a display panel, a neck, and a supporting base.
[0009] FIG. 2 is an exploded view of the display device of FIG. 1 .
[0010] FIG. 3 is a side plan view of the display device of FIG. 1 , showing that the display panel can be moved up or down, and back or forth relative to the supporting base.
[0011] FIG. 4 is a front plan view of the display device of FIG. 1 , showing that the display panel can be rotated in a plane substantially perpendicular to the supporting base.
[0012] FIG. 5 is an enlarged view of the neck of FIG. 2 , the neck including a lifter.
[0013] FIG. 6 is an isometric, exploded view of the neck of FIG. 5 , the neck further including a first sliding stand, a hinge, a second tilting stand, and a rotating apparatus.
[0014] FIG. 7 is an enlarged view of the first sliding stand, the hinge, and the second tilting stand of FIG. 6 .
[0015] FIG. 8 is an assembled, cutaway view of FIG. 7 , showing the hinge attached to the second tilting stand.
[0016] FIG. 9 is an enlarged view of a circled portion IX of FIG. 8 .
[0017] FIG. 10 is an exploded view of the rotating apparatus and the second tilting stand of FIG. 6 .
[0018] FIG. 11 is similar to FIG. 5 , but not showing the lifter.
[0019] FIG. 12 is a side plan view of a conventional display device.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
[0020] Reference will now be made to the drawings to describe preferred and exemplary embodiments in detail.
[0021] Referring to FIG. 1 and FIG. 2 , a display device 2 according to an exemplary embodiment of the present invention is shown. The display device 2 includes a supporting base 21 , a neck 23 , and a display panel 25 . The supporting base 21 supports the neck 23 and the display panel 25 . The neck 23 interconnects the display panel 25 and the supporting base 21 . Referring also to FIG. 3 and FIG. 4 , the neck 23 is configured for allowing the display panel 25 to be moved up or down, pivoted back or forth relative to the supporting base 21 (as shown in FIG. 3 ), and rotated in a plane substantially perpendicular to the supporting base 21 (as shown in FIG. 4 ), as desired.
[0022] Referring also to FIG. 5 and FIG. 6 , the neck 23 includes a supporting stand 231 , a first sliding stand 233 , a second tilting stand 234 , a hinge 235 , a rotating apparatus 237 , a locking stand 238 , and a lifter 239 .
[0023] The supporting stand 231 includes a first side plate 2311 , a second side plate 2313 , a third side plate 2315 , and two bottom plates 2316 . The first side plate 2311 and the third side plate 2315 are located at two opposite sides of the supporting stand 231 , and are interconnected by the second side plate 2313 . The bottom plates 2316 are connected with the first side plate 2311 and the third side plate 2315 , respectively. A first blocking strip 2312 inwardly extends from the second side plate 2313 . The supporting stand 231 further includes a first sliding guide 2317 fixed at an inner surface (not labeled) of the first side plate 2311 , and a second sliding guide 2319 fixed at an inner surface (not labeled) of the third side plate 2315 .
[0024] Referring also to FIG. 7 , the first sliding stand 233 is configured to be received in the supporting stand 231 , and includes a top board 2331 , a first side board 2333 , a second side board 2335 , a first sliding arm 2337 , and a second sliding arm 2339 . The first side board 2333 and the second side board 2335 are located at two opposite sides of the first sliding stand 233 , and are interconnected by the top board 2331 . The first sliding arm 2337 is fixed at an outer surface (not labeled) of the first side board 2333 , and is configured to slide along the first sliding guide 2317 . The second sliding arm 2339 is fixed at an outer surface (not labeled) of the second side board 2335 , and is configured to slide along the second sliding guide 2319 . Each of the first side board 2333 and the second side board 2335 includes a first flat through hole 2332 and a first flat fixing hole 2334 defined therein, respectively.
[0025] The lifter 239 includes a roller 2391 and a belt 2393 . The roller 2391 is positioned at a top end of the lifter 239 far from the bottom plates 2316 . The belt 2393 includes one end fixed to the roller 2391 , and the other end fixed to the top board 2331 of the first sliding stand 233 . Typically, the roller 2391 is spring-loaded. Thereby, when the roller 2391 is rotated in a first direction such that the belt 2393 extends further out from the roller 2391 , the roller 2391 elastically resists such rotation. The amount of resistance increases with increasing extension of the belt 2393 out from the roller 2391 . In one alternative embodiment, the belt 2393 can be an elastically deformable (stretchable and recoverable) belt.
[0026] The second tilting stand 234 is configured to be received between the first side board 2333 and the second side board 2335 of the first sliding stand 233 . The second tilting stand 233 includes a first side wall 2343 corresponding to the first side board 2333 , a second side wall 2345 corresponding to the second side board 2335 , and a front wall 2341 interconnecting the first side wall 2343 and the second side wall 2345 . Each of the first side wall 2343 and the second side wall 2345 defines a second rounded through hole 2342 corresponding to the first flat through hole 2332 , and a second flat fixing hole 2344 corresponding to the first flat fixing hole 2334 , respectively. The front wall 2341 includes a second blocking strip 2349 outwardly extending from a main body thereof, and a third rounded through hole 2347 and a fourth rounded through hole 2348 defined in the main body, respectively.
[0027] The hinge 235 includes a first spindle 2350 , and two screw cap assemblies 2351 configured to be threadedly engaged to two opposite ends (not labeled) of the first spindle 2350 . The first spindle 2350 includes a flat main portion (not labeled) and the two threaded ends. The screw cap assembly 2351 includes a first washer 2353 , a second washer 2355 , and a screw cap 2357 . The first washer 2353 includes an annular first body (not labeled), and a third blocking strip 2354 perpendicularly extending from an edge of the first body. The third blocking strip 2354 extends in a direction away from the middle of the first spindle 2350 , and corresponds to the first flat fixing hole 2334 . The second washer 2355 includes an annular second body (not labeled), and a fourth blocking strip 2356 perpendicularly extending from an edge of the second body. The fourth blocking strip 2356 extends in a direction toward the middle of the first spindle 2350 , and corresponds to the second flat fixing hole 2344 . That is, the third blocking strip 2354 and the fourth blocking strip 2356 point in opposite directions.
[0028] Referring also to FIG. 8 and FIG. 9 , when the hinge 235 is assembled to the second tilting stand 234 , the first spindle 2350 extends through the first flat through holes 2332 and the second rounded through holes 2342 . One pair of the first and second washers 2353 , 2355 are located between the first side board 2333 and the first side wall 2343 , the other pair of first and second washers 2353 , 2355 are located between the second side board 2335 and the second side wall 2345 . The third blocking strips 2354 are received in the first flat fixing holes 2334 , and the fourth blocking strips 2356 are received in the second flat fixing holes 2344 , respectively. The screw caps 2357 are threadedly engaged to the opposite ends of the first spindle 2350 , and are located outside the first side board 2333 and the second side board 2335 , respectively. With the above-described configuration, the first spindle 2350 is non-rotatable relative to the first sliding stand 233 , and is rotatable relative to the second tilting stand 234 . Therefore the second tilting stand 234 can correspondingly move up or down when the first sliding stand 233 moves up or down along the supporting stand 231 , and the first sliding stand 233 can remain static relative to the supporting stand 231 when the second tilting stand 234 and the first spindle 2350 are pivoted back or forth relative to the supporting stand 231 .
[0029] The locking stand 238 is substantially rectangular, and includes a fifth through hole 2381 corresponding to the fourth through hole 2348 , a curved sliding groove 2382 corresponding to the second blocking strip 2349 , and two sixth through holes 2383 defined in a central portion thereof, respectively. The sliding groove 2382 and the sixth through holes 2383 are located on two opposite sides of the fifth through hole 2381 . The locking stand 238 further includes a plurality of seventh through holes (not labeled) defined in four corners thereof such that the display panel 25 can be fixed to the locking stand 238 via the seventh through holes and a plurality of fasteners such as fixing bolts (not shown).
[0030] Referring to FIG. 10 , the rotating apparatus 237 includes a second spindle 2370 , a third washer 2371 , a fourth washer 2372 , a driving gear 2373 , a third spindle 2374 , a fifth washer 2375 , a driven gear 2376 , a rotatable block 2377 , a static block 2378 , and a connecting line 2379 . The driven gear 2376 includes a plurality of first teeth (not labeled) meshed with a plurality of second teeth (not labeled) of the driving gear 2373 .
[0031] The third washer 2371 includes two fifth blocking strips (not labeled) corresponding to the sixth through holes 2383 , respectively. The second spindle 2370 includes an enlarged flat head (not labeled), and a main body (not labeled) connected with the flat head. The main body of the second spindle 2370 includes a flattened and threaded end corresponding to an eighth through hole (not labeled) of the driving gear 2373 . When the display device 2 is assembled, the main body of the second spindle 2370 extends through the fifth through hole 2381 , the fourth through hole 2348 , the third washer 2371 , the fourth washer 2372 , a plurality of gaskets (not labeled) located between the fourth washer 2372 and the driving gear 2373 , and the eighth through hole of the driving gear 2373 . A screw cap (not labeled) is threadedly engaged to the threaded end of the second spindle 2370 . The fifth blocking strips of the third washer 2371 are non-rotatably received in the sixth through holes 2383 , respectively. With the above-described configurations, the second spindle 2370 is non-rotatable relative to the driving gear 2373 , and is rotatable relative to locking stand 238 . Therefore when the second spindle 2370 is rotated, the driving gear 2373 is correspondingly rotated.
[0032] The third spindle 2374 extends through the driven gear 2376 and the rotatable block 2377 , and is parallel to the second spindle 2370 . The third spindle 2374 is non-rotatable relative to the driven gear 2376 and the rotatable block 2377 . A threaded end (not labeled) of the third spindle 2374 extends through the third through hole 2347 and the fifth washer 2375 , and is threadedly engaged to a screw cap (not labeled). The fifth washer 2375 includes a sixth blocking strip (not labeled) received in a ninth through hole (not labeled) above the third through hole 2347 .
[0033] Referring also to FIG. 11 , the static block 2378 is fixed at a top portion of the supporting stand 231 . The connecting line 2379 includes one end (not labeled) fixed to the supporting stand 231 , and the other end (not labeled) connecting to the rotatable block 2377 . A section (not labeled) of the connecting line 2379 is movably received over a top of a pulley wheel (not labeled) of the static block 2378 . In the illustrated embodiment, the connecting line 2379 is a kind of flexible cord.
[0034] In one use, an external force is applied to the display panel 25 and the locking stand 238 to move the display panel 25 up or down relative to the supporting base 21 . As described above, the locking stand 238 moves up or down relative to the supporting base 21 , and the first sliding stand 233 correspondingly moves up or down along the supporting stand 231 . When the display panel 25 reaches a desired position, the external force is released, and the display panel 25 and the locking stand 238 can remain at the desired position due to a balance of a pulling force from the roller 2391 , a static friction force between the first and second sliding guides 2317 , 2319 and the first and second sliding arms 2337 , 2339 , respectively, and related gravitational forces. In addition, the first blocking strip 2312 can limit a maximum height of the display panel 25 .
[0035] In another use, an external force is applied to the display panel 25 and the locking stand 238 to pivot the display panel 25 back or forth relative to the supporting base 21 . As described above, the first sliding stand 233 remains static relative to the supporting stand 231 , and the second tilting stand 234 is moved back or forth about the first spindle 2350 correspondingly. When the display panel 25 is pivoted to a desired position, the display panel 25 can remain at the desired position due to a balance of static friction forces between the pairs of first and second washers 2353 , 2355 .
[0036] In a further use, an external force is applied to the display panel 25 and the locking stand 238 to rotate the display panel 25 in the plane substantially perpendicular to the supporting base 21 . As described above, the rotation of the locking stand 238 drives the second spindle 2370 to rotate, and the third spindle 2374 and the rotatable block 2377 rotate correspondingly. Therefore, the display panel 25 can be rotated in the plane, and a maximum angle of the rotation of the display panel 25 depends on a length of the sliding groove 2382 . When the display panel 25 reaches a desired position, the display panel 25 can remain at the desired position due to a balance of friction forces associated with, inter alia, the meshing connection between the driven gear 2376 and the driving gear 2373 . In addition, when the display panel 25 is rotated, the display panel 25 can be driven to move up relative to the supporting base 21 at the same time in the case that one corner of the display panel 25 interferes with the supporting base 21 .
[0037] In summary, the neck 23 allows the display panel 25 to be moved up or down, pivoted back or forth relative to the supporting base 21 , and rotated in the plane substantially perpendicular to the supporting base 21 , as desired. Therefore, desired view angles, view heights, and view rotations of the display panel 25 can be conveniently achieved. This enables the display device 2 to readily provide optimum viewing positions for the display panel 25 .
[0038] It is believed that the present embodiments and their advantages will be understood from the foregoing description, and it will be apparent that various changes may be made thereto without departing from the spirit or scope of the invention or sacrificing all of its material advantages, the examples hereinbefore described merely being preferred or exemplary embodiments of the invention. | An exemplary display device includes a display panel and a rotating apparatus. The rotating apparatus includes a first spindle assembly, a conveyor connecting to the first spindle assembly, and a second spindle assembly. The first spindle assembly includes a first spindle configured to synchronously rotate with rotation of the display panel. The second spindle assembly includes a second spindle meshed with the first spindle, and is configured to be able to rotate and simultaneously rise or fall along the connecting assembly. | 5 |
This is a continuation application of patent application Ser. No. 08/520,059, filed Aug. 28, 1995, now U.S. Pat. No. 5,725,951 for LUBRICANT AND SOIL RELEASE FINISH FOR YARNS. Specific reference is being made herein to obtain the benefit of its earlier filing date.
BACKGROUND OF THE INVENTION
This invention relates to a yarn which has been treated with a lubricant and soil release finish composition prior to fabric formation, particularly to a yarn which has been treated with an oil-in-water emulsion finish.
Prior to fabric formation, synthetic yarn and yarn blends containing synthetic fibers are typically processed to provide increased strength, stretch and bulk, and to enhance their appearance. The processing steps may include heating and drawing to provide a degree of orientation to the yarns, as well as texturing with mechanical action. After the yarns have been modified as desired, a lubricant is applied to reduce friction during subsequent processing steps, such as winding, weaving or knitting.
It is well known to improve the washability and moisture transport properties of fabrics made from synthetic fibers by treating the fabric with a "soil release agent". In one example, a soil release agent, which is the condensation product of dimethyl terephthalate, ethylene glycol and polyethylene glycol, is added to the bath during jet dyeing of polyester, and the agent is exhausted into the fibers of the fabric. Following the dyeing step, the fabric is rinsed, dried and heat set.
One of the shortcomings of the prior art process is that the soil release agent is applied to the fabric during the dye cycle. Accordingly, it has been necessary to process the fabric in the dyeing equipment, even if the fabric is not going to be dyed, for the sole purpose of providing the soil release treatment. Another shortcoming is that it is that the soil release agent is applied after fabric formation. Accordingly, when the yarn is sent to different locations to be woven or knitted, or if the yarn is sold, each location is required to have its own equipment for applying the soil release agent.
SUMMARY OF THE INVENTION
Therefore, one of the objects of the invention is to provide a soil release treatment which need not be exhausted into the fabric. Another object of the invention is to provide a soil release treatment which may be applied to the yarns prior to fabric formation. Still another object of the invention is to combine application of the lubricant finish and soil release finish in a single step.
Accordingly, a finish composition is provided, which incorporates a lubricating oil and a soil release agent and is applied to a yarn as an oil-in-water emulsion. The lubricant protects the yarn during subsequent processing steps, such as winding and fabric formation. The soil release agent improves the washability and moisture transport properties of the yarn and fabrics made therefrom.
Additionally, the invention may be characterized by one or more of the following features:
yarn to yarn friction of 33 to 39 grams of output tension;
yarn to metal friction of less than 50 grams of output tension at a contact angle of 180°; and
textured continuous filament polyester yarn.
Advantages of the present invention include:
a decrease in the amount of lubricant required, as the soil release agent provides lubrication to the yarn; and
elimination of unnecessary process steps, since the soil release properties may be imparted to a yarn by application of a soil release agent under ambient conditions.
DETAILED DESCRIPTION OF THE INVENTION
Without limiting the scope of the invention, the preferred embodiments and features are hereinafter set forth. Unless otherwise indicated, all parts and percentages are by weight and conditions are ambient i.e. one atmosphere of pressure and 25° C. The terms aryl and arylene are intended to be limited to single and fused double ring aromatic hydrocarbons. Unless otherwise specified, aliphatic hydrocarbons are from 1 to 12 carbon atoms in length, and cycloaliphatic hydrocarbons comprise from 3 to 8 carbon atoms.
In the present invention, the soil release agent is applied to a yarn, prior to fabric formation, along with a lubricant. The yarn may be a continuous multifilament yarn or spun yarn. The yarn will typically have a denier ranging from 30-300 and have a filament count ranging from 10-200, preferably 15-100. The denier and the filament count are not deemed to be critical to the practice of the invention, and yarns outside the stated ranges may be used.
A wide variety of natural and synthetic fibers may be employed. By way of example the fiber substrate may be selected from polyamide fibers, including nylon, such as nylon 6 and nylon 6,6, and aramid fibers; polyester fibers, such as polyethylene terephthalate (PET); polyolefin fibers, such as polypropylene; polyurethane fibers; blends of the aforementioned synthetic fibers; and blends of such synthetic fibers with cellulosic fibers, such as cotton, rayon and acetate. Preferably, the fiber has a hydrophobic component and is selected from polyamide fibers, polyester fibers or polyester/cotton blends.
The finish composition applied to the yarn contains a lubricating oil to facilitate subsequent processing of the yarn, such as winding, warping and fabric formation, and a soil release agent to enhance the performance of the textile article made from the yarn. The finish composition is applied to achieve a lubricant add on, including emulsifiers necessary to form a stable emulsion, of from 0.15 to 6 wt % on the weight of the fiber (owf), preferably 0.375 to 2% owf; and a soil release agent add on of from 0.05 to 3.0% owf, preferably 0.075 to 0.75% owf.
Satisfactory results are achieved with emulsions containing 45 wt % or greater, preferably, 50 wt % or greater water and compositions having the following ranges may be employed:
1 to 49.7 wt. % of a lubricating oil;
0.3 to 49 wt. % of a soil release agent;
50 to 95 wt. % water; and
up to 5 wt. % auxiliaries.
Preferably, the composition is an emulsion having from:
2.5 to 29.5 wt. % of a lubricating oil;
0.5 to 25 wt. % of a soil release agent;
70 to 95 wt. % water; and up to 3 wt. % auxiliaries. The concentration of lubricating oils is intended to include the emulsifiers necessary to form a stable emulsion of the oil.
The auxiliaries, biocides, antistatic agents, anti-sling agents, and wetting agents, and their use in fiber finishes well known to those skilled in the art.
The invention may be practiced with a wide variety of conventional lubricating oils. By way of example, suitable oils include:
(a) mineral oil derivatives which include paraffinic, alicyclic and aromatic hydrocarbons and combinations thereof, the molecular weights of the mineral oils typically range from 175-1000;
(b) synthetic oils including:
(i) organic esters such as C 6 -C 18 esters of fatty acids, particularly dibasic esters derived from C 6 -C 10 diacids esterified with C 6 -C 10 alcohols and esters of higher polyols such as triglycerides and esters of pentaerythritol;
(ii) alkoxylated fatty acids and alcohols, primarily propylene oxide and ethylene oxide adducts of C 10 -C 18 organic acids and alcohols;
(iii) low molecular weight polyolefins, which are liquid at ambient conditions, such as polyisobutylene and polyalphaolefins; and
(iv) silihydrocarbon oils.
Reference may be made to the Kirk-Othmer, Encyclopedia of Chemical Technology, 3rd Edition, Volume 14, page 477 et. seq. "Lubrication and Lubricants" (1981); Ross et al, U.S. Pat. No. 4,995,884; and Plonsker, U.S. Pat. No. 4,932,976.
Conventional soil release agents may be employed in the composition of the present invention. The soil release agents are characterized by a macromolecule having a hydrophilic component, such as a carboxyl, hydroxyl, alkali metal sulfonate and/or oxyethylene group, and a lipophilic component with an affinity for the fiber, which functions to add durability or to anchor the soil release agent to the fiber surface. The backbone of the macromolecule is generally formed by either vinyl polymerization or condensation reaction. Molecular weights may range from 500 to 100,000, preferably from 1,000 to 25,000, most preferably 1,000 to 10,000.
By way of example, suitable soil release agents include:
(a) non-ionic soil release agents having oxyethylene hydrophiles, such as the condensation polymers of polyethylene glycol and/or ethylene oxide addition products of acids, amines, phenols and alcohols which may be monofunctional or polyfunctional, together with binder molecules capable of reacting with the hydroxyl groups of compounds with a poly(oxyalkylene) chain, such as organic acids and esters, isocyanates, compounds with N-methyl and N-methoxy groups, bisepoxides etc. Particularly useful are the condensation products of dimethyl terphthalate, ethylene glycol and polyethylene glycol (ethoxylated polyester) and ethoxylated polyamides, especially ethoxylated polyesters and polyamides having a molecular weight of at least 500, as well as the soil release agents described in the following patents, U.S. Pat. No. 3,416,952; U.S. Pat. No. 3,660,010; U.S. Pat. No. 3,676,052, U.S. Pat. No. 3,981,807; U.S. Pat. No. 3,625,754; U.S. Pat. No. 4,014,857; U.S. Pat. No. 4,207,071; U.S. Pat. No. 4,290,765; U.S. Pat. No. 4,068,035 and U.S. Pat. No. 4,937,277.
(b) anionic soil release agents particularly, vinyl polymers containing carboxylic acid as the hydrophile as can be obtained by polymerizing acrylic acid, methacrylic acid or maleic acid, usually with a comonomer such as an alkyl acrylate, preferably methyl or ethyl acrylate, to increase the lipophilic character of the polymer and to decrease brittleness. Cross-linking improves the durability of the soil release agent, and accordingly, it is desirable to copolymerize with a cross-linking agent such as N-methyl acrylamide, or to cross-link the polymer with a small amount of a bisepoxide. Examples of representative anionic soil release agents may be found in the following patents: U.S. Pat. No. 3,377,249; U.S. Pat. No. 3,535,141; U.S. Pat. No. 3,540,835; U.S. Pat. No. 3,563,795; U.S. Pat. No. 3,598,641; U.S. Pat. No. 3,574,620; U.S. Pat. No. 3,632,420; U.S. Pat. No. 3,650,801; U.S. Pat. No. 3,652,212; U.S. Pat. No. 3,690,942; U.S. Pat. No. 3,897,206; U.S. Pat. No. 4,090,844; and U.S. Pat. No. 4,131,550.
(c) combinations of anionic soil release agents with oxyethylene hydrophile condensates, such as are generally referred to as sulfonated ethoxylated polyesters and the soil release agents disclosed in the following patents: U.S. Pat. No. 3,649,165; U.S. Pat. No. 4,073,993; and U.S. Pat. No. 4,427,557.
(d) nonionic soil release agents with hydroxyl hydrophiles, particularly cellulose derivatives such as cellulose acetate and the soil release agents disclosed in the following patents: U.S. Pat. No. 3,620,826; U.S. Pat. No. 4,164,392; and U.S. Pat. No. 4,168,954.
The soil release agent may be in the form of an emulsion, dispersion or solution. Preferably, the soil release agent has a nonionic hydrophilic component and is in the form of an aqueous dispersion or aqueous solution.
All of the United States patents heretofore listed are incorporated by reference herein.
The lubricating oil and soil release agent are combined, along with the desired ancillary additives, to form an oil-in-water emulsion using conventional techniques. Preferably, the soil release agent is in the form of an aqueous dispersion, solution or emulsion, as are commercially available. For example, first an emulsion of the lubricant and water is formed by vigorous agitation with a laboratory stirrer, and next, the soil release agent may be added while continuing to agitate the composition. It may be desirable to improve the stability of the emulsion by incorporating surface active agents (surfactants) or emulsifiers into the composition, as is well known to those skilled in the art. Suitable emulsifiers include nonionic, ionic and zwitterionic surfactants, such as alkoxylated alcohols, alkyl phenols, fatty acids and amides; carboxylate, sulfonates and phosphate esters, quaternary compounds and those surfactants disclosed in the Kirk-Othmer Encyclopedia of Chemical Technology, 3rd Edition, Surfactants and Detersive Systems, pp. 332-432 (1983). If an emulsifier is necessary to stabilize the finish composition, the emulsifier may be employed at a ratio of emulsifier to oil of from about 1:20 to 2:1, preferably 1:10 to 1:1.
The lubricant/soil release finish composition may be applied at any stage of yarn processing that a lubricant alone could be applied. Prior to application of the finish, the yarn may be subjected to various treatments, such as one or more of the following: drawing, twisting, heat setting, entanglement or crimping. In a preferred embodiment, the finish is applied at the texturing frame to textured polyester yarn made from drawn partially oriented yarn (POY).
The finish may be applied by conventional techniques used to apply a lubricant emulsion to yarn. By way of example, the finish of the present invention may be applied from a kiss roll, metered applicator, sprayer, or by immersion. The add on of finish composition (as is) ranges from 1 to 30 wt. % owf, preferably from 3 to 15 wt. % owf, most preferably from 3 to 8 wt % owf.
Following application of the present finish to the yarn, the yarn may be handled and processed as are yarns treated with conventional lubricants. For example, the yarn may be wound into a package and then formed into a fabric, preferably a woven knitted fabric, as is well known in the art. The yarn or fabric may be scoured, heat set and even dyed. One of the advantages of the present process is that it is particularly useful when the yarn or fabric is not dyed. Since the soil release agent is applied early in the yarn processing process, the dyeing step can be eliminated when it is desirable to do so. Surprisingly, the performance and durability of the soil release treatment is not adversely affected by omission of the dyeing step, or other treatment in a heated aqueous bath, which was once thought necessary to exhaust the soil release agent into the fiber, before soil release properties could be achieved.
The invention may be further understood by reference to the following examples, but the invention is not to be construed as being unduly limited thereby.
EXAMPLE 1
The following example demonstrates the washability and moisture transport performance of a fabric constructed of yarn, which has been treated with the lubricant/soil release agent emulsion of the present invention.
A partially oriented polyester yarn, 150/34, was heated, drawn and textured. At the texturing frame, a lubricant/soil release agent finish was applied in emulsion form to the yarn to achieve 1 wt %, 2 wt % or 3 wt % (owf), on a neat basis. The composition of the finish was 3.2 wt % of an ethoxylated polyester soil release agent, identified as lubril QCX™ available from Rhone Polenc; 20 wt % of an emulsified ester lubricant, identified as Synlube™ 6340 available from Milliken Chemical, U.S.A.; and 76.8 wt % water.
For each level of finish, the yarn was knitted into a sock and the sock was cut in half. One half of the sock was scoured in a 120° F. home wash (12 minute "cotton/sturdy" wash cycle in a residential washing machine with detergent present). The scoured and unscoured halves of fabric, Samples A and B, respectively, were then dyed blue (Resolin Blue GFL) in a disperse dye cycle (130° C. for 30 minutes) on a Mathis laboratory jet dyeing machine.
The fabrics were then tested for soil release using corn oil according to AATCC Test Method 130-1977, and moisture transport according to AATCC Test Method 39-1977. The soil release test is designed to measure the ability of a fabric to release oily stains during home laundering. Briefly, a sample fabric is stained with corn oil and washed under conventional home laundry conditions. The samples are then rated on a scale from 1-5, with 1 representing the poorest stain removal and 5 representing the best stain removal.
The moisture transport or wettability test measures the time it takes for a fabric to absorb a drop of water, while the fabric is held taut and horizontal. The time it takes for the drop to completely absorb into the fabric is measured in seconds, with a stop watch, and recorded. A high number is indicative of slow absorption, and thus poor wettability. The fabric made from yarn treated with the lubricant/soil release agent finish of the present invention was compared to fabrics made from yarn treated with a lubricant finish only, which was knitted, cut in half and one half only was scoured, Samples C and D. The results for 1 wt % (owf) finish levels are reported in Table 1.
TABLE 1______________________________________Sam- Finish Soil Release Wettabilityple Treatment Finish Level Scour? Rating (1-5) (Seconds)______________________________________A lubricant/soil 1 wt % (owf) scour 4.5 1release agentB lubricant/soil 1 wt % (owf) no 4.8 1release agent scourC lubricant 1 wt % (owf) scour 2.8 >30D lubricant 1 wt % (owf) no 3.0 >30 scour______________________________________
EXAMPLE 2
The procedures of Example 1 were repeated except that an equal amount of an emulsified hydrocarbon lubricant, identified as Lube Stat™ 5101 available from Milliken Chemical, U.S.A., was substituted for the lubricant in the lubricant/soil release agent finish. The results of finish applications at 1 wt %, 2 wt % and 3 wt % (owf), on a neat basis, are reported below in Table 2.
EXAMPLE 3
The procedures of Example 1 were repeated except that an alkoxylated lubricant, identified as Syn Lube™ 6278, available from Milliken Chemical, U.S.A., was substituted for the lubricant in the lubricant/soil release agent finish. The results of finish applications at 1 wt %, 2 wt % and 3 wt % (owf), on a neat basis, are reported below in Table 2.
TABLE 2______________________________________Finish Composition(Sample) Add On (owf) Soil Release Rating (1-5)______________________________________Example 1 1 wt % 4.5(Sample A) 2 wt % 5.0 3 wt % 4.8Example 2 1 wt % 5.0 2 wt % 5.0 3 wt % 5.0Example 3 1 wt % 5.0 2 wt % 5.0 3 wt % 5.0______________________________________
EXAMPLE 4
The following example shows variation of the relative proportion of lubricant, soil release agent in water, and the affect the variation has on friction and soil release properties.
The procedures of Example 1 were repeated, except that the components of the lubricant/soil release agent finish of Example 1 was varied as shown in Table 3 below, and designated E, F and G. Also included in Table 3 are the test results for Sample A of Example 1, and the test results for a control yarn which had been treated with a producer supplied primary lubricant finish at approximately 0.3 wt % owf.
Yarn-to-metal and yarn-to-yarn friction was evaluated using a Rothschild frictometer. The finish composition was applied to 150 denier/34 filament, textured polyester yarn, at a conventional texturing frame, at the level specified. The yarn was allowed to condition for at least 24 hours at 72° F. and 63% humidity. After conditioning, the hydrodynamic yarn-to-metal friction was obtained on the frictometer at a speed of 100 meters/minute at a contact angel of 180° and pre-tensions of 20 grams, Yarn-to-yarn friction was evaluated at the above conditions, with the exception that the friction pin was bypassed and the yarn was given two full twists.
TABLE 3______________________________________ Soil Soil Release Lubri- Release Yarn to Yarn to (1Sam- Add On cant Agent Water Yarn Metal poorestple (owf) (wt %) (wt %) (wt %) Friction Friction5 best)______________________________________A 1 wt % 20 3.2 76.8 33 33.5 4.52 wt % 20 3.2 76.8 31 26.5 53 wt % 20 3.2 76.8 32 26.5 4.8E 1 wt % 15 3.75 81.25 40 47 52 wt % 15 3.75 81.25 34 31 53 wt % 15 3.75 81.25 33 28.5 5F 1 wt % 10 4.5 85.5 38 44.5 52 wt % 10 4.5 85.5 33 33.5 53 wt % 10 4.5 85.5 33 29.5 5G 1 wt % 5 5.3 89.7 36 44.5 52 wt % 5 5.3 89.7 34 34.5 53 wt % 5 5.3 89.7 34 31.5 5Con- -- -- -- -- 42.5 34.5 1trol______________________________________
EXAMPLE 5
The following example demonstrates the efficacy of the lubricant/soil release composition on an undyed textile.
The lubricant/soil release composition of Sample A and G were applied at levels of 1, 2 or 4 wt % (owf), on a neat basis, to a polyester yarn, 150/34, made from recycled polyethylene terephthalate fiber.
The treated yarn was then knitted into a sock and test for soil release according to AATCC Test Method 130-1977. The results were compared against a control fabric made with yarn to which only a primary finish had been applied, i.e. lubricant only at about 1 wt % (owf) on a neat basis. The results are summarized below in Table 4, with a Soil Release Rating of "5" being the best and "1" being the poorest.
TABLE 4______________________________________Sample Add On (owf) Soil Release (1-5)______________________________________Control Primary Finish Only 3.0A 1% 3.5A 2% 4.5A 4% 5.0G 1% 3.5G 2% 5.0G 4% 5.0______________________________________
There are, of course, many alternative embodiments and modifications of the invention which are intended to be included within the scope of the following claims. | An improved textile yarn finish is provided having a continuous aqueous phase with a soil release agent incorporated therein and a discontinuous phase of a lubricating oil. | 3 |
FIELD OF THE INVENTION
[0001] This invention relates to a method of preparing dialysed aqueous extract of fenugreek seeds which induces hypoglycemia, mediated, in part, via stimulation of insulin signaling pathway.
BACKGROUND OF INVENTION
[0002] Diabetes mellitus is an alarming medical problem affecting more than 194 million people. Persisting diabetic conditions often lead to damage of blood vessels, increased risk of coronary artery disease, myocardial infarction, atherosclerosis, claudication and stroke, blindness, nerve damage and in extreme situations may event lead to amputations. The principal cause of these complications is hyperglycemia mainly due to lack of insulin, or insulin resistance, or defects in insulin signaling pathways.
[0003] Management of diabetes focuses mainly on several approaches intended to sustain reduction in hyperglycemia that reduces the risk of developing microvascular and macrovascular complications. In addition to insulin. control of hyperglycemia mainly involves use of biguanides, sulfonylureas, D-phenylalanine derivatives, meglitinides, peroxisome proliferator-activated receptor-γ (PPAR-γ) agonists (thiazolidine diones) and α-glucosidase inhibitors. These drugs augment insulin secretion from pancreatic islets, act to reduce hepatic glucose production, interfere with gut glucose absorption or enhance insulin action, suppress glucose production and augments glucose utilization. The efficacies of these compounds are still under debate due to either side effects or many patients who respond initially become refractory to treatment over a period of time. Considering the multifactorial nature of diabetes that can not be ascribed to a single genetic or environmental change but arise from a combination of genetic, environmental or behavioral factors, alternative approaches are necessary for better management. Extracts of seeds and leaves of fenugreek have been historically known for their antihyperglycemic activity and non-toxicity. Though hypoglycemic effects of fenugreek have been attributed to several factors and mechanisms, its active principles have been only partially purified viz., trigonelline and 4-hydroxyisoleucine, which account for the antidiabetic activity in part. They are shown to be act by enhancing insulin secretion from islets of Langerhans. So far no attempts have been made to explore the possibility of insulin mimicking effect of fenugreek seeds extract at cellular and molecular level.
[0004] Fenugreek and other traditional plants are currently being investigated for their potential as a source of new hypoglycaemic compounds for the treatment of diabetes. However, with the exception of guanidine, many of the hypoglycaemic compounds isolated from plants are small molecules such as alkaloids, flavanoids, glycosides, steroids, aminoacids or minerals that are not suitable for pharmaceutical drug development. However, medicinal plant extracts used for treating hyperglycemia might contain number of components that together contribute to over-all effectiveness. Therefore isolating individual component from such extracts may not be as effective.
OBJECTS OF THE INVENTION
[0005] An object of this invention is to propose a method of preparing dialysed aqueous extract of fenugreek seeds.
[0006] An object of this invention is to prepare a dialysed aqueous extract of fenugreek seeds which stimulates glucose dependent pancreatic insulin secretion.
[0007] Still another object of this invention is to propose a dialysed aqueous extract of fenugreek seeds which activates insulin signaling pathway in adipocytes and liver that enhance glucose uptake.
[0008] Further object of this invention is to prepare a dialysed aqueous extract of fenugreek seeds which enhances glucose utilization by the activation of liver glucokinase enzyme.
[0009] Still further object of this invention is to give a scientific validation for the hypoglycemic activity using innovative strategies.
Statement of the Invention:
[0010] According to this invention this is provided a method of preparing a dialysed aqueous extract of fenugreek seeds comprising
[0000] washing the fenugreek seeds in distilled water,
sterilizing the said seeds,
subjecting the sterilized seeds to the step of grinding to fine powder,
suspending the said powder in phosphate buffered saline (PBS),
subjecting the said suspension to the step of filtration to obtain the filtrate,
treating the filtrate with activated charcoal to obtain clear supernatant,
subjecting the supernatant to the step of lyophilization and the powder thus obtained was dissolved in phosphate buffered saline (PBS),
dialyzing the aqueous extract of fenugreek seeds to obtain dialysed fenugreek seed extract (FSE) which was aliquoted and stored.
[0011] This invention highlights the fact that the said dialysed fenugreek seed extract (FSE) does possess in vivo hypoglycemic activity.
[0012] The hypoglycemic effect was associated with significant enhancement in liver glucokinase activity.
[0013] Hypoglycemic effect was sustained for further five days following consecutive administration of said extract for five days.
[0014] Dialysed aqueous extract of fenugreek seeds potentiated the glucose-dependent insulin secretion in normal mouse islets and increased GLUT4 translocation dependent glucose uptake in cells.
[0015] Similar to insulin, the said extract induced tyrosine phosphorylation of a number of proteins including insulin receptor, IRS-1 and p85 subunit of PI3-Kinase, in both 3T3-L1 adipocytes and hepatoma cell line, HepG2.
[0016] Therefore the hypoglycemic activity of dialysed aqueous extract of fenugreek seeds is a cumulative effect of three independent actions; 1) it stimulates glucose dependent pancreatic insulin secretion, 2) metabolic effects in adipocytes and liver that enhances glucose uptake mediated via activation of insulin signaling pathway and, 3) enhances glucose utilization by activation of liver GK enzyme. Also, the in vitro models and methods described in this study could be used for screening the activity of natural compounds suitable for the development of new antidiabetic drugs.
BRIEF DESCRIPTION OF THE ACCOMPANYING DRAWINGS
[0017] FIG. 1 : The in vivo effectiveness of FSE was studied in diabetic fasted BALB/CJ or Swiss albino mice in which diabetes was induced by injecting multiple doses of STZ or AXN.
[0018] FIG. 2 : Acute and chronic administration of FSE for 5 days in diabetic Swiss albino mice decreases blood serum glucose and improves bodyweight.
[0019] FIG. 3 : Effect of FSE on intraperitoneal glucose tolerance test (IPGTT) in normal Swiss albino mice.
[0020] FIG. 4 : Glucose stimulated insulin release from isolated islets of Langerhans is potentiated by FSE.
[0021] FIG. 5 : Effect of FSE on glucose transport in cells. FSE treatment exhibited a dose dependent increase in glucose transport rates in this cell based model.
[0022] FIG. 6 : Analysis of FSE induced GLUT4 translocation.
[0023] FIG. 7 : Effect of FSE on GLUT4 translocation and specificity in 3T3-L1 adipocytes. Pretreatment with wortmannin and BIS-1 masked there effects.
[0024] FIG. 8 : Effect of FSE on cellular phosphorylation and insulin signaling proteins in 3T3-L1 adipocyte and HepG2 cells. Cellular phosphorylation pattern of both cell lines demonstrated that the effects of extract on cellular proteins are comparable to those induced by insulin.
[0025] FIG. 9 : FSE is not a general tyrosine kinase activator of receptors. FSE failed to activate EGF receptor as treatment did not increase the autophosphorylation of it.
[0026] FIG. 10 : Effects of FSE are independent of Akt activation. Effect of insulin and extract on activation of Act shows significant differences.
[0027] FIG. 11 : To investigate the link between FSE induced IR phosphorylation and GLUT4 translocation, translocation of PKC ) was studied in both 3T3-L1 and HepG2. Significant amount was detected in membrane fraction.
[0028] FIG. 12 : A model for cellular effects of fenugreek seeds extract on glucose homeostasis.
DETAILED DESCRIPTION OF THE INVENTION
[0029] Preparation of Fenugreek Seeds Extract. Fenugreek Seeds were Washed in distilled water, surface sterilized by soaking for 30 seconds in 0.1% sodium hypochlorite and 0.05% nonidet P-40 and rinsing thoroughly with distilled water. Seeds were ground to fine powder in mixer at chilled conditions, and Suspended in PBS (pH 7.4) containing 1 mol/l PMSF and protease inhibitor cocktail. The extract was filtered through three-layered cheesecloth. Filtrate was treated with activated charcoal, kept on ice for 1 h and centrifuged at 15,000×g at 4° C. for 30 min and clear supernatant was lyophilized. The powder was dissolved in PBS and dialyzed in 8000 Dalton cut off dialysis membrane for 24 h with 6 hourly changing of PBS. This preparation is referred as FSE. The FSE was aliquoted and stored at −70° C. for long term and this was used for all further experiments.
[0030] In vivo antihyperglycemic activity of dialyzed FSE in chemically induced diabetic animal models. BALB/cJ or Swiss albino mice (male, 8-10 week old) were housed under environmentally controlled conditions (22+/−2° C.) with a 12 h light/dark cycle and had free access to standard rodent pellet food and water. Animals were given 5 daily intraperitoneal (IP) injection of freshly prepared STZ (40 mg/kg in 0.5 molt sodium citrate pH 4.5) or AXN (50 mg/kg in 0.9% sodium chloride). Ten hours before the experiments, animals were moved to new cages in which no food was available. AXN injected mice that achieved a glucose level of 200-300 mg/dl and STZ injected mice that achieved a glucose level of 275-400 mg/dl were used as hyperglycemic models in this study. Mice were divided into, diabetic control group, insulin group and FSE group (n=5 in each group). Mice were injected (IP) with vehicle (PBS), insulin (1.5 U/kg) or extract (1, 5 or 15 mg/kg). Blood was collected before injection (0 min), 90 and 240 min after the treatments and serum blood glucose levels were estimated. In some experiments STZ-BALB/cJ mice were sacrificed 90 min after the treatments, and the livers were harvested for analysis. In another set of experiments, AXN-induced Swiss albino diabetic mice were injected with PBS or extract for 5 days (n=5). Blood was collected on day 0, 5, 10 and 15 and body weight was monitored on same day. Acidified insulin from bovine pancreas diluted in PBS was used as a positive test compound in all the experiments. All animal experiments have been performed following the requirement of the committee for the Purpose of Control and Supervision of Experiments on Animals (CPCSEA), Government of India, and after permission of the Institute's Animal Care and Use Committee (IACUC).
[0031] Effect of FSE on intraperitoneal glucose tolerance test (IPGTT) in normal animals. The IPGTT was performed by IP injection of 3 g/kg of glucose after 10 h fasting to induce hyperglycemia (n=5). Blood collected before the injection of glucose was considered as basal. Fifteen mg/kg FSE was injected 10 min after the injection of glucose. Same dose of FSE was injected to normoglycemic (glucose unloaded) mice. Blood samples were collected at 45, 90 and 180 min after the administration of extract and blood glucose levels were estimated.
[0032] Glucokinase assay. Liver samples were homogenized in three volumes of ice cold buffer containing 50 mmol/l Tris-HCl, pH 7.4, 300 mmol/l sucrose, 100 mmol/l KCl, 1 mmol/l EDTA 2.5 mmol/1 mercaptoethanol and centrifuged at 12,000×g for 15 min (12). The resulting supernatants were centrifuged at 180,000×g for 60 min. This cytosolic fraction was used to assay GK activity, by a spectrophotometric assay essentially as described previously (23). GK activity was calculated as the difference between the glucose phosphorylation capacity at 100 and 0.5 mmol/l glucose. Enzyme activity is indicated as nmol.min −1 .mg −1 of protein.
[0033] Effect of FSE on insulin secretion in islets. Group of five Swiss albino mice weighing 18-20 g were sacrificed, pancreata were removed aseptically, and islets were prepared as described previously (24) by digestion of pancreas with a collagenase solution (BSA 2%, trypsin inhibitor Type II 0.2%, collagenase Type IV 0.1%, in DMEM) for 20 min. Islets were maintained in RPMI supplemented with 10% FBS, 100 U/ml penicillin 100 μg/ml streptomycin at 37° C. in 5% CO 2 After 48 h, islets were washed thrice with Krebs Ringer buffer (KRB) (120 mmol/l NaCl, 5 mmol/l KCl, 2.5 mmol/l CaCl 2 , 1.1 mmol/l MgCl 2 , 25 mmol/l NaHCO3. pH7.4) by centrifugation at 1000×g. Islet viability was assessed by trypan blue staining and specificity of islets was determined by dithiozone (0.01%) staining for 10 min at 3 7C. Hundred islets were preincubated in KRB containing 0.1% BSA and 3.3 mmol/l glucose for 1 h at 37° C. in 5% CO 2 . Subsequently islets were incubated for additional 1 h with or without FSE in presence of 16.7 mmol/l glucose. Culture supernatants were collected and assayed for the insulin by using ultrasensitive mouse insulin ELISA kit (Mercodia, Uppsala, Sweden)
[0034] Cell Culture In Vitro Studies. 3T3-L1 preadipocytes (ATCC no. CL-173) and HepG2 cells (ATCC no. HB-8065) were maintained in 100 mm coated petri plates in DMEM containing 25 mmol/l glucose and 10% NBCS or PBS respectively. For preadipocyte differentiation 80% confluent preadipocytes were cultured for 2 days in differentiation medium (DMEM supplemented with 1 μmol/l insulin, 0.5 mmol/l IBMX, 0.25 μmol/l DEX containing 10% FBS) and for 2 days in DMEM supplemented with 1 μmol/l insulin and 10% FBS. Thereafter the cells were grown for an additional 4-5 days in DMEM containing 10% FBS. Media was changed on every second day without any additional supplements. CHO clones expressing insulin receptor and GLUT4eGFP protein were grown in media supplemented with hygromycin additionally (100 μg/ml). Penicillin (100 units/ml) and streptomycin (100 mg/ml) were added routinely to cultures and all cell lines were cultivated at 37° C. in a 5% CO 2 enriched humidified atmosphere.
[0035] Effect of FSE on glucose transport. CHO clones expressing insulin receptor and GLUT4eGFP were grown in 24 well plates, serum starved for 3 h in DMEM containing 0.1% BSA and washed twice in KRB buffer (137 mmol/l NaCl, 4.7 mmol/l KCl, 10 mmol/l sodium phosphate pH 7.4, 0.5 mmol/l MgCl 2 , 1 mol/l CaCl 2 , 2 mg/ml BSA) at 37° C. for 30 min (25). Cells were then treated with insulin or FSE for an additional 10 and 30 min respectively. The glucose uptake reaction was initiated by adding 0.1 mmol/l 2-deoxy glucose containing 0.5 μCi/ml 2-DG. After incubation at 37° C. for 4 min, the reaction was terminated by washing tree times with ice-cold PBS buffer containing 20 mmol/l D-glucose, and solubilized with 0.1% SDS. Protein was estimated and the radioactivity incorporated into cells was quantified by scintillation counting (Packard, Albertville, Minn.). Nonspecific uptake, measured in the presence of 10 μmol/l cytochalasin B, was subtracted from all values. To examine the specificity of the signaling pathway cells were pre-treated with 100 mmol/l wortmannin, a P13-K inhibitor, for 20 min or 100 nmol/l BIS-1, a PKC specific inhibitor for 1 h and followed by treatment with extract additional 30 min.
[0036] GLUT4 Translocation Assay in GLUT4 Overexpressing Cell lines. CHO clones expressing insulin receptor and GLUT4eGFP protein were plated on a microscopic chamber slide (ICN, Costa Mesa, Calif.), serum starved in DMEM containing 1 mg/ml BSA for 3 h, followed by treatment with 100 nmol/l insulin or 25 mg/l FSE for 10 and 30 min respectively. Treatment was terminated by keeping the slide on ice and washing with cold PBS. Cells were fixed with 3% para-formaldehyde (PF) in PBS for 15 min at room temperature. GLUT4 translocation was investigated by using LSM confocal microscope (Zeiss LSM 510, Heidelberg, Germany). 3T3-L1 expressing mycGLUT4 were grown in 96 well plated then differentiated to adipocytes, serum starved for 3 h and incubated with insulin or FSE for 10 and 30 min respectively. To examine the specificity of the signaling 2u pathway the cells were pretreated with wortmannin (100 nmol/l) or BIS-1 (100 nmol/l) for 20 min and 1 h respectively. The reaction was terminated by keeping the plate on ice and washing with cold PBS followed by fixing the cells with 3% PF for 3 min and then neutralized with 1% glycine in PBS at 4° C. for 10 min (26, 27). After blocking the cells with 5% skimmed milk in PBS at room temperature for 30 min, cells were incubated with 1:200 dilution of monoclonal anti-myc antibody at 4° C. for overnight. Cells were washed with PBS-T (PBS containing 0.05% Tween 20) and subsequently incubated with peroxidase conjugated goat anti-mouse IgG (1:1000, 4° C.) for 1 h. Following the removal of secondary antibody, cells were incubated with 5% ABTS containing 1% H 2 O 2 in citrate buffer pH 4.2. The optical absorbance of the supernatant was measured at 414 nm.
[0037] Effect of FSE on insulin signaling proteins in 3T3-L1 Adipocytes and HepG2 cell lines. Differentiated 3T3-L1 adipocytes or HepG2 cell were serum starved in F-12K medium containing 7 mM glucose and 0.1% BSA for 16 h followed by changing medium to DMEM containing 25 mmol/l glucose and incubated for 1 h. Subsequently the cells were treated with 100 nmol/l insulin or 25 mg/l FSE for 10 min and 30 min respectively. 15Untreated cells were incubated with PBS. Cells were washed with cold PBS, removed from the plates using a rubber policeman, lysed in lysis buffer (50 mmol/l Tris-HCl pH7.5, 150 mmol/l NaCl, 1% NP-40, 2 mmol/l EGTA, 2 mmol/l Na 3 VO 4 , 100 mmol/l Na 4 P 2 O 7 , 50 mmol/l okadaic acid, 1 mmol/l PMSF and protease inhibitor cocktail) on ice for 30 min, passed through 261/2G syringe 20 times and finally centrifuged at 15,000×g for 10 min at 4° C. Equal amounts of protein (100 μg) were diluted in 5× Laemmli reducing buffer (250 mmol/l Tris-HCl p 6.8, 10% SDS, 0.5% bromophenol blue, 50% glycerol, 12.5% β-mercaptoethanol) boiled for 5 min at 100° C. and resolved by 8% SDS-PAGE by running proteins below 43 kDa out of the gel. The proteins form the gel were transferred to nitrocellulose membrane using transfer buffer (CAPS buffer pH 10.7 containing 10% methanol) by applying 150 mA current for 2 h. Thereafter membranes were washed and blocked with 5% BSA or non fat skimmed milk in tris-buffered saline (TBS) (10 mmol/l Tris-HCl pH7.5, 1.5 mol/l NaCl) for overnight at 4° C., washed with TBS-T (TBS containing 0.1% Tween-2-), incubated with anti-phosphotyrosine antibody or anti-phospho-Akt (Ser-473)-R or (Thr308)-R antibody for 2 h at room temperature, washed extensively, incubated with peroxidase conjugated secondary antibody and processed for enhanced chemiluminescence. For reprobing, membranes were washed (62.5 mmol/l Tris-HCl (pH 6.7), 2% w/v SDS and 100 mmol/l β mercaptoethanol) for 30 min at 50° C., and incubated with either anti-IR-α or anti-IRβ or anti-IRS-1, or anti-p85 or anti-Akt antibody.
[0038] Confocal microscopy analysis of PKC translocation in HepG2 cells. HepG2 cells were serum starved for 3 h and were treated with either 100 nmol/l insulin for 10 min or 25 mg/l FSE for 30 min. In some wells, cells were pretreated with pharmacological inhibitors before treating with extract. Cells were washed quickly with cold PBS and fixed by treating with 3% paraformaldehyde in PBS Ph 7.4, for 15 min at room temperature, rinsed with PBS three times and quenched with 1% glycine for 10 min. Cells were permeabilised with 0.025% saponin in PBS, for 5 min, blocked with PBS containing 5% FBS for 1 h at room temperature, incubated with anti-PKC antibody for overnight at 4° C. in PBS oontaining 2.5% FBS. Cells were washed four times for 5 min each with PBS. Cells were then incubated with a flourescein isothoicyanate conjugated anti-rabbit antibody for additional 1 h, washed again and mounted using vectashield (Vector Laboratories, Burlingame, Calif.) for visualization by confocal microscopy. Rabbit IgG was used as an isotype control.
[0039] Isolation of plasma membrane fraction and immunoblotting detection of PKCλ and GLUT4 in 3T3-L1 adipocytes. Differentiated 3T3-L1 cells in 100 mm petri dishes were serum starved for 3 h in DMEM supplemented with 0.1% BSA and then treated with 100 nmol/l insulin or 25 mg/ml FSE for 10 min and 30 min respectively. In some cases cells were pre-treated with 100 nmol/l wortmannin, for 20 min or 100 nmol/l BIS-1 for 1 h followed by treatment with extract t for additional 30 min. Plasma membrane fractionation of 3 T3-L1 adipocytes was performed as previously described (28) with slight modifications that 1 mmol/l PMSF, 1 mmol/l Na 3 VO 4 and a cocktail of protease inhibitors were added to the lysis buffers. Equal protein was diluted with 5× Laemmli buffer, electrophoresied by 10% SDS-PAGE and transferred on to a nitrocellulose membrane. The membrane was probed with anti-nPKCλ or anti-GLUT4 antibody. EGFR auto phosphorylation in A431 cells. A-431 epidermal carcinoma cells (ATCC no. CRL-1555) were maintained in DMEM containing 10% FBS, serum starved followed by treatment with 50 nmol/l epidermal growth factor (EGF) (Promega, Madison, Wis.), or FSE for the indicated period of time. The cells were washed with PBS, lysed, and equal amount (50 μg) of protein were resolved by SDS-PAGE, transferred to nitrocellulose membrane, blocked, and probed with antiphosphotyrosine antibody. Same membrane was stripped and reprobed with anti-EGFR antibody.
[0040] Antidiabetic effect of fenugreek seeds extract is currently under intense investigation. Though few factors like trigonelline and 4-hydroxyisoleucine, which exhibit hypoglycemic effect, have been reported, none of them have reached a stage for human use. Based on the literature, we felt that the whole FSE extract may function more efficiently than certain individual components. Therefore, we attempted to understand the mechanism of action of FSE, which will be of immense use for ascertaining the antidiabetic potential of FSE. Though the American Diabetes Association encourages the use of traditional medicines, the World Health Organization (WHO) expert committee on Diabetes Mellitus recommended that clinical use of traditional antidiabetic plants warrant further evaluation. So far none of the studies have simultaneously investigated effect of FSE or any other plant extract on various pathways involved in glucose metabolism and regulation. The data presented in FIG. 1 , clearly demonstrates that FSE significantly improves glucose homeostasis in different diabetic mice strains obtained by injection of multiple doses of either AXN or STZ. At a dose of 15 mg/kg FSE produced a 50-60% decrease in fasting blood glucose level. In addition FSE also improved intraperitoneal glucose tolerance by effectively lowering blood glucose in normal Swiss albino mice after they were injected with glucose solution. It is pertinent to test the maintenance of lower blood glucose levels with long-term treatment rather than the acute hypoglycemic effect after a single does. The present study demonstrates that antidiabetic potential of the FSE remained effective for 10 days without significant loss in body weight after 5 consecutive FSE injections in AXN induced diabetic mice ( FIG. 2 ).
[0041] Insulin secreted by islets of Langerhans, in response to increase blood glucose level, acts on target tissues viz adipose tissue and liver. Glucose homeostasis is lost because of combined defects in insulin secretion and insulin action leading to hyperglycemia. In our present study we report that FSE treatment in diabetic animals for 90 min results in the activation of GK by 3.5 fold compared to control treated animals. Under the similar experimental conditions insulin treatment resulted in an increase in GK activity by 4.5 fold which is marginally higher than FSE treated mice. Moreover, GK activity in FSE treated diabetic mice was even higher than that of healthy non-diabetic control mice (Table 1). These results clearly suggest that one of the mechanisms by which FSE treatment leads to glucose lowering effects is via activation of glucose metabolizing enzyme in the liver.
[0042] To explain the 50-60% reduction in blood glucose level after the administration FSE, the mechanisms by which FSE ameliorates hyperglycemia was further investigated in vitro. The effect of FSE on pancreas and target tissues of insulin viz., liver and adipocytes, were explored using in vitro models and its effects were compared with that of insulin. Firstly, effect of FSE on insulin secretion by mouse islets was investigated. As shown in FIG. 4 , FSE potentiated the insulin secretion induced by glucose treatment in a dose dependent manner. At a dose of 25 mg/l FSE, insulin secretion increased by ˜1.5 fold. Since normoglycemic animals were not sensitive to the glucose-lowering effects caused by extract ( FIG. 3B ), the mechanism of action of FSE is partly dependent on blood glucose level, which is a hallmark for diabetic condition.
[0043] Glucose uptake by target tissues of insulin is the rate-limiting step in type 2 diabetes. This transport is facilitated mostly by translocation of glucose transporter form intracellular site to the plasma membrane in the target tissues. Using stable clones overexpressing GLUT4 as an in vitro model system, we demonstrate that FSE treatment induces a rapid stimulation of cellular glucose uptake by activating cellular responses that lead to glucose transporter translocation to cell surface ( FIGS. 6 , 7 A and B). In comparison to insulin treatment, the potency of FSE in stimulating glucose uptake was less by 35% (P<0.05 vs. insulin; FIG. 4B ). In 3T3-L1 cells overexpressing GLUT4 treatment with FSE increased GLUT4 translocation increased by 1.4 fold in comparison to the basal levels of GLUT4. Under similar experimental conditions, 100 nmol/l insulin treatment enhanced the glucose uptake by 2.5 fold. These results suggest that the factor(s) in FSE, in addition to stimulating GK and potentiating insulin secretion. The action of insulin is initiated by binding to the insulin receptor, which leads to activation of its receptor tyrosine kinase and autophosphorylation (6). Similarly, treatment of HepG2 and 3T3-L1 cells, with 25 mg/l FSE activated the tyrosine phosphorylation of 1R-β and subsequently enhancing phosphorylation of downstream signaling molecules like IRS-1 as well as p85 subunit of P13-kinase. FSE had no effect on IR-α phosphorylation. Moreover, FSE treatment activated specifically the IR signaling pathway since, it did not enhance EGF receptor autophosphorylation ( FIG. 9 ). Therefore, FSE can act as an insulin mimetic molecule and it is not a general sensitizer of receptor tyrosine kinase domains.
[0044] Activation of P13-K is necessary for the metabolic action of insulin, action of insulin, as demonstrated in studies using P13-K inhibitors wortmannin. Pretreatment of cells with wortmannin inhibited GLUT4 translocation as well as glucose uptake ( FIG. 5B , FIGS. 7A and B). Insulin elicited signals resulting in activation of P13-K are transmitted by two independent pathways; an Akt pathway and a PKC pathway, down stream of P13-K (9). FSE treatment had no effect on Thr-308 or Ser-473 phosphorylation of Akt in both 3T3-L1 and HepG2 cells ( FIG. 10 ). However FSE treatment did activate translocation of PKCλ in both 3T3-L1 adipocytes and HepG2 cells ( FIGS. 11A and B). To further confirm the involvement of PKCλ, pretreatment of cells with wortmannin and BIS-1, a PKC specific inhibitor inhibited translocation of PKCλ induced by FSE. Therefore, in contrast to involvement of PKCλ and Akt in insulin stimulated GLUT4 translocation (11), FSE mediated GLUT4 translocation involved only PKC) FSE regulates multiple targets involved in maintaining glucose homeostasis. It facilitates insulin secretion form pancreas, enhances liver GK activity. Both in muscles and liver cells, FSE induces phosphorylation of 1R, 1RS-1 and P13-K. This results in stimulation PKC and translocation of glucose transporters culminating in increases in glucose uptake ( FIG. 12 ).
[0045] In conclusion, we have clearly shown in the present study that FSE, which has been used as a traditional medicine for diabetes, exhibited three types of antihyperglycemic effects: 1) it stimulated glucose dependent pancreatic insulin secretion, 2) metabolic effects in adipocytes and liver that enhanced uptake and, 3) enhanced glucose utilization by the activation of liver GK enzyme. Hence, the antidiabetic property of FSE is due to activation multiple pathways that control its glucose metabolism activity. This is a first report in which antidiabetic effect of any plant extracts has been thoroughly investigated and its mechanism of action unraveled. The study provides a starting point for revaluation usefulness of traditional medicinal plants for controlling hyperglycemia in diabetic condition.
Examples
[0046] Effect of FSE on diabetic mice. Hypoglycemic activity of plant extracts and other synthetic compound is conventionally assessed by inducing stable diabetes mellitus in a suitable animal and observing the changes in either fasting blood glucose (FBS) of by the intrapritoneal glucose tolerance test (IPGTT) in normal animal (29,30). The in vivo effectiveness of FSE was studied in diabetic fasted BALB/cJ or Swiss albino mice in which diabetes was induced by injecting multiple doses of STZ- or XN. The extract exhibited antihyperglycemic activity in a dose dependent manner, in both BALB/cJ and Swiss albino AXN-diabetic mice ( FIGS. 1A and B). Injecting (I(P) 15 mg/kg FSE decreased blood glucose levels to normal by 4 h in both STZ and AXN induced diabetic mice. Overall 50-60% reduction was observed as compared to diabetic control (P<0.01). The peak effect occurred at 90 min after the administration of extract and the effects were comparable to that of 1.5 U/kg insulin. In STZ diabetic mice, blood glucose level decreased by 30%, in 90 min after the administration of FSE and it further lowered to half by 4 h ( FIG. 1C ). Blood glucose levels after 10 h of fasting in diabetic mice were measured on day 0, and 5, 10 and 15, after five consecutive intraperitoneal injections of 15 mg/kg FSE. As shown in FIG. 2A , the diabetic animal had significantly higher fasting blood glucose levels on day zero (239.5+/18.25 mg/dl). On day 5, the blood glucose concentration decreased significantly in diabetic mice treated with FSE and the mice became normoglycemic (136+/−29.5 mg/dl; P<0.01 vs. PBS-10 treated mice, 245+/−8.3 mg/dl). In extract treated mice, the antihyperglycemic effect of extract sustained up to tend days (160+/−14.5) without significant reduction in body weight (from 26.5+/−0.54 g on day zero to 25.5+/−0.41 g on day 10) as compared to diabetic animal group (from 27.0+/−0.4 g on day zero to 22.5+/−0-0.6 g on day 10; FIG. 2B ). On day 15 the blood glucose level rose gradually to 184+/−20 mg/dl.
[0047] Effect of FSE on IPGTT in normal animals. The effect of FSE on IPGTT in normal Swiss albino mice was studied. We used 3 g/kg glucose to obtain a serum glucose level of ˜25 mmol/l. As shown in FIG. 3A , 45 min after the administration of 15 mg/kg FSE, the rise in serum blood glucose level in experimental animal group (311.44+/−38.5) was significantly inhibited (P <0.01) as compared to the control group injected with PBS (549.44+/−11.69 mk/dl). Surprisingly, FSE had no effect on serum blood glucose level in glucose unloaded normoglycemic mice ( FIG. 3B ).
[0048] Effect of FSE on liver glucokinase activity. The GK activity in STZ-diabetic mice is extremely low due to partial or total deficiency of insulin resulting in derangement of carbohydrate metabolism. As insulin administration normalizes these alterations, activities of these enzymes represent a method to assess the effect of FSE on peripheral utilization of glucose. Since the extract showed a peak activity at 90 min after the administration, we explored the effect of FSE on GK activity at this time point. As expected STZ-diabetic BALB/cJ mice showed a significant reduction in the activity of GK by 47% in comparison with normal animal. 1 o Extract at a dose of 15 mg/kg enhanced the activity by 360% (P<0.01) as compared to diabetic control (Table). Further more, insulin treatment in diabetic mice improved GK activity by 460%.
[0049] Effect of FSE on insulin secretion in islets. Reduction in glucose level by 40-60% in diabetic mice by FSE raises the question as to whether or not the extract influences the insulin secretion for the observed antihperglycemic activity. To test this hypothesis, we studied the effect of FSE on isolated mouse islets of Lnagerhans. Islets were incubated in stimulating buffer (16.7 mM Glucose) for 60 min in the presence and absence of extract. When studied over a dose range, extract potentiated insulin secretion from islets in a gradual and dose dependent manner ( FIG. 4 ). At a dose of 25 mg/l extract, insulin secretion increased by 48% (P<0.05).
[0050] Effect of FSE on glucose transport in GLUT4 overexpressing cells. Stable clone of CHO and 3T3-L1 cell lines that overexpress proteins involved in insulin signaling partway have been widely employed to study insulin induced glucose uptake and GLUT4 translocation (35-37). CHO cells overexpressing insulin receptor as well as GLUT4 were incubated in the presence of various concentrations of FSE for 30 min and glucose transport was measured by determining the rates 2DG uptake. FSE treatment exhibited a dose dependent increase in glucose transport rates of in this cell based model. The maximal effect was observed at 25 mg/l (270% of basal; P<0.05; FIG. 5A ). However, the potency of FSE was 35% less than insulin, in stimulating glucose uptake (P<0.05 vs. insulin; FIG. 5B ) and FSE stimulated glucose uptake was abrogated by pretreating cells with wortmannin and BIS-1. To assess if the ability of FSE to enhance glucose transport involves GLUT4, its translocation was studied in GLUT4 overexpressing CHO- and 3T3-L1 cells by confocal microscopy, by ELISA and by membrane fractionation in 3T3-L1 adipocytes. FSE induced a significant increase in the GLUT4 fluorescence on the membrane of CHO-cells overexpressing insulin receptor as well as GLUT4 ( FIG. 6 ), enhanced GLUT4 content in the membrane fraction of 3T3-L1 cells and, the translocation has increased by 50% in 3T3-L1 cells overexpressing GLUT4 P<0.05 vs. Basal). Pretreatment with wortmannin and BIS-1 masked these effects ( FIGS. 7A and B).
[0051] Effect of FSE on cellular phosphorylation and insulin signaling proteins in 3T3-L1 adipocyte and HepG2 cells. The differentiated 3T3-L1 adipocytes, HepG2 cells, a human hepatoma cell line, are the classical model to elucidate the mechanism of action of antihyperglycemic compounds or plant extract. Activation of 1R by insulin results in increased phosphorylation of a number of proteins including, 1RS-1 and p85 subunit of P13-K. To explore the mechanism of action of action of FSE in differentiated 3T3-L1 adipocytes and HepG2 cells, they were treated with the 25 mg/l extract or 100 nmol/l insulin. Lysate from treated cells were subjected to western blot analysis using phosphoprotein specific antibodies. Cellular phosphorylation pattern of both cell lines demonstrated that the effects of extract of cellular proteins are comparable to those induced by insulin ( FIG. 8 ). Similar to insulin treated cells, extract treated cells also did not exhibit 1R-α phosphorylation. Whereas the phosphorylation of 1R-β and 1RS-1 and a major band at 85 kDa was comparable in both extract as well as insulin treated cells. Therefore it is reasonable to assume that the FSE induced phosphorylation pattern was similar in both HepG2 and 3T3-L1 cells.
[0052] The IR belongs to a family of receptor tyrosine kinase that shares high degrees of homology in the tyrosine kinase domain. Activation of receptor kinase leads to a wide variety of biological effects ranging from metabolic regulation to deleterious neoplastic transformation. To confirm the specificity of and to rule out that extract is a general receptor kinase activator, we tested the effect of extract on phosphorylation of EGF receptor in A431 cells. FSE failed to activate EGF receptor as treatment did not increase the autophosphorylation of it ( FIG. 9 ). This data indicates that activation by the FSE is specific to 1R and its downstream signaling molecules in 3T3-L1 and HepG2 cells and hence, is not a general receptor tyrosine kinase activator.
[0053] Effect of FSE on PKCλ translocation in 3T3-L1 and RepG2 cells. Since Akt has been shown to be involved in insulin stimulated GLUT4 translocation we investigated the effect of PSE on Akt activation. Effect of insulin and extract on activation of Akt shows significant differences ( FIG. 10 ). Extract did not induce Akt phosphorylation at Ser473 or Thr-308. To investigate the link between FSE induced 1R phosphorylation and GLUT4 translocation, translocation of PKCλ was studied in both 3T3-L1 and HepG2. Significant amount of PKCλ was detected in membrane fraction of FSE treated 3T3-L1 as compared to PBS treated ( FIG. 11A ). In unstimulated HepG2 cells the immunofluorescence was minimum as visualized by confocal microscopy. In contrast, stimulation of cells with FSE for 30 min resulted in maximum immunofluorescence on the cell surface and it was indistinguishable form that produced by treating cells with 100 nmol/l insulin for 10 min ( FIG. 11B ). This change in translocation are consistent with insulin dependent translocation of PKCλ from cytosol to cell surface. Wortmannin and bis-1 decreased the fluorescence associated with the membrane. This data indicates that extract acts through P13-K dependent pathway and thereby mediates PKCλ translocation.
[0000]
TABLE 1
FSE enhances liver GK activity in STZ-BALB/cJ mice.
Non-diabetic
Diabetic
Insulin
FSE
control
control
treated
treated
GK activity
475.6 +/−
122.8 +/−
690.0 +/−
566.6 +/−
nmol · min −1 · mg −1
13.6
11.6
22.3*
20.3*
Liver was removed 90 min after the treatments and assayed for GK activity as described in RESEARCH DESIGN AND METHODS. (*P < 0.01 vs. diabetic control) | A method of preparing dialysed aqueous extract of fenugreek seeds comprising washing the fenugreek seeds is distilled water, sterilizing the said seeds, subjecting the sterilized seeds to the step of grinding to form powder, suspending the said powder in phosphate buffered saline (PBS), subjecting the said suspension to the step of filtration to obtain the filtrate, treating the filtrate with activated charcoal to obtain clear supernatant, subjecting the supernatant to the step of lyophilization and the powder thus obtained was dissolved in phosphate buffered saline (PBS), dialyzing the aqueous extract of fenugreek seeds to obtain dialysed fenugreek seed extract (FSE) which was aliquoted and stored. | 0 |
CROSS REFERENCE TO RELATED APPLICATIONS
This is a National Stage Application of PCT/US 03/19516 under 35 USC §371(a), which claims priority of U.S. Provisional Patent Application Ser. No. 60/390,106 filed Jun. 19, 2002, now abandoned, the entire contents of which are hereby incorporated by reference.
BACKGROUND
1. Technical Field
The present disclosure relates to apparatus and methods used for joining tissue portions and more particularly, to anastomotic devices and methods for positioning and joining two hollow body parts.
2. Background of Related Art
Anastomosis is the bringing together and/or joining of two hollow or tubular structures. When it is desired to suture a body conduit, typically for attachment to another body conduit, sutures are placed around the circumference of the conduit in order to maintain the patency of its lumen or channel. It can be appreciated that the sutures made on top of the conduit (i.e., on the side facing the surgeon) are made relatively more easily than the sutures made underneath the conduit (i.e., on the side facing away from the surgeon).
The complexity of joining two body vessels is made manifestly apparent in a surgical procedure referred to generally as a radical prostatectomy (i.e., a well established surgical procedure for patients with localized prostatic carcinoma). In general, radical prostatectomy procedures require the removal of cancerous tissue while preserving sexual function and continence in the patient. There are two primary types of radical prostatectomy approaches for the removal of prostate cancer, the retropubic approach and the perineal approach.
In the retropubic approach, a long up-and-down incision is made in the midline of the abdomen from the navel to the pubic bone. After the lymph nodes have been removed for study by the pathologist and a determination has been made to proceed with the removal of the prostate gland, the space underneath the pubic bone is cleaned and dissected and the removal of the entire prostate gland is generally begun at the end that is farthest from the bladder, i.e., next to the external urethral sphincter. Next, the prostatic urethra is divided, the prostatic urethra and the prostate gland through which it goes are then pulled upwards toward the bladder while the dissection continues behind the prostate gland, separating it from the layer of tissue that is connected to the rectum on its other side. As the dissection continues between the prostate and the rectum, the seminal vesicles, which are behind the base of the bladder, will be removed along with the prostate gland. Once the seminal vesicles are free, the entire prostate gland and the seminal vesicles are removed. The bladder neck is then stitched closed to a small enough diameter so that it is about the same size as the stump of the urethra from which the prostate was detached. The bladder neck is then pulled down into the pelvis and positioned against the urethral stump and stitched thereto. This stitching is done typically around a Foley catheter which has been inserted through the penis all the way into the bladder.
In the perineal approach, an inverted “U” shaped incision is made going right over the anus, with the center of the “U” about three centimeters above the margin of the anus. The prostate gland is then freed from its surrounding structures by gentle dissection, and the urethra at the end of the prostate farthest from the bladder is isolated and divided. The bladder neck is freed from the prostate, and, once the prostate gland has been removed and the bladder neck has been closed sufficiently so that the size of its opening approximates the size of the urethral opening, the urethra and the bladder neck are stitched together. Once again, a Foley catheter is left in place postoperatively for about two weeks.
In each of the above described procedures, it is the attachment of the urethral stump to the bladder neck which is particularly difficult and complex. This difficulty is complicated by the tendency of the urethral stump to retract into adjacent tissue. As a result, considerable time and effort must be expended to re-expose the urethral stump and begin the re-anastomosis procedure. Further complicating this procedure is the fact that the urethral stump is hidden beneath the pubic bone thus requiring that the surgeon work at a difficult angle and in positions that are uncomfortable and limiting.
Various devices have been proposed for facilitating this procedure. In U.S. Pat. No. 5,591,179, issued to Edelstein, there is disclosed a suturing device including a shaft with portions defining an interior channel extending between a proximal and a distal end of the shaft. This channel includes a generally axial lumen which extends to the proximal end of the shaft and a generally transverse lumen which extends from the axial lumen distally outwardly to an exit hole at the outer surface of the shaft. A needle and suture can be back loaded to the transverse lumen of the channel while a generally non-compressible member can be movably mounted in the axial lumen of the channel. At the proximal end of the shaft a handle is provided with means operative to push the member distally through the lumen to deploy or expel the needle.
In U.S. Pat. No. 4,911,164, issued to Roth, there is disclosed a suture guide with a curved distal portion. The distal portion of the suture guide has a plurality of exterior axial grooves which can be used to align and guide a curved needle and attached suture. In order to drive the urethral stump to an accessible position, the device is provided with a plurality of outwardly extendable members which engage the lumen of the urethra. These members make it possible to push the urethral stump into approximation with the bladder neck.
In U.S. Pat. No. 5,047,039, issued to Avant et al., there is disclosed a surgical device for the ligation of a dorsal vein and subsequent anastomosis. This device contains a pair of enclosed needles each having an attached suture which needles may be driven from the shaft of the device into adjacent tissue.
In general, none of the devices disclosed in the prior art references above is simple to use or makes the anastomosis of the urethral stump to the bladder neck easier. As such, each surgical procedure using prior art devices continues to be time consuming and requires great skill in order to be performed. Accordingly, the need exists for anastomosis devices which overcome the drawbacks of the prior art devices and which are quick and simple to use.
SUMMARY
Apparatus and methods for performing a surgical anastomotic procedure are disclosed herein. According to one aspect of the present disclosure, an apparatus for approximating body vessels includes at least one fastener. Each fastener includes a first fastener portion having an anchoring leg portion, and a second fastener portion having an anchoring leg portion, wherein the first and second fastener portions are operatively associated with one another for selectively fixing the position of the first fastener portion and the second fastener portion with respect to one another. The apparatus further includes a first member configured and adapted to engage the first fastener portion, and a second member configured and adapted to engage the second fastener portion, the first member and the second member being movable with respect one another to move the first fastener portion and second fastener portion with respect to one another.
It is envisioned that each first fastener portion and second fastener portion has a locking leg portion and a first position in which the anchoring leg portion is adjacent the locking leg portion and a second position in which the anchoring leg portion is spaced a distance from the locking leg portion.
Each of the anchoring leg portions of the first and second fastener portions can include a sharpened tip, wherein the sharpened tips are oriented substantially toward one another. Each anchoring leg portion can be integrally connected to the respective locking leg portion.
In certain embodiments, the apparatus further includes an insertion sleeve. Accordingly, it is envisioned that each anchoring leg portion can be biased to a position spaced from the respective locking leg portion and collapsible to a position in close proximity to the respective locking leg portion.
It is envisioned that each fastener can be made from stainless steel, titanium, polyglycolic acid and polylactic acid.
In certain embodiments, the first fastener portion and the second fastener portion include inter-engaging fixing elements. The fixing elements can include a series of projections formed along a surface of the first fastener portion, and a locking passage formed along a surface of the second fastener portion, the locking passage being configured and dimensioned to receive an end of the first fastener portion therein. The locking passage can include at least one projection extending from an inner surface thereof and the at least one projection is configured and dimensioned to engage the series of projections formed along the surface of the first fastener portion. Desirably, the fixing elements are saw toothed. Accordingly, the fixing elements permit movement of the first fastener portion relative to the second fastener portion in a first direction, while preventing movement in a second direction.
It is envisioned that each of the first fastener portion and the second fastener portion can have a locking leg portion pivotably connected to the respective anchoring leg portion.
Each anchoring leg portion can include a suture secured thereto.
In certain embodiments, the apparatus can further include an insertion sleeve. It is envisioned that a plurality of fasteners can be radially disposed about the lumen of the insertion sleeve.
It is envisioned that each first fastener portion can include a lip extending from the first fastener portion and the first member can include an anvil having a hook formed at a distal end thereof for engaging the lip of the first fastener portion. It is further envisioned that each second fastener portion can include a lip extending from the second fastener portion and the second member can include a pusher having a recess formed in a distal end thereof for engaging the lip of the second fastener portion.
In certain embodiments, the apparatus can further include fixing elements on each of the first and second fastener portions. The fixing elements can include a series of projections formed along a surface of the first fastener portion, and a locking passage formed along a surface of the second fastener portion, the locking passage being configured and dimensioned to receive an end of the locking leg portion of the first fastener portion therein. The locking passage includes at least one projection extending from an inner surface thereof which at least one projection is configured and dimensioned to engage the series of projections formed along the surface of the first fastener portion. The locking passage is defined by a pair of side walls extending from the locking leg portion of the second fastener portion and an end wall interconnecting and extending between the pair of side walls, the at least one projection of the locking passage being formed on an inner surface of the end wall.
According to another aspect of the present disclosure, a method of approximating a first body vessel and a second body vessel is provided. The method includes the step of providing an apparatus for approximating the first body vessel and the second body vessel. The apparatus includes at least one fastener having a first fastener portion having an anchoring leg portion, and a second fastener portion having an anchoring leg portion, wherein the first and second fastener portions are operatively associated with one another for selectively fixing the position of the first fastener portion and the second fastener portion with respect to one another, a first member configured and adapted to engage the first fastener portion, and a second member configured and adapted to engage the second fastener portion, the first member and the second member being movable with respect to one another to move the first fastener portion and second fastener portion with respect to one another.
The method further includes the steps of passing the apparatus through the first body vessel and through an opening in the second body vessel such that the anchoring leg portion of the first fastener portion is positioned within the second body vessel, withdrawing the first member to drive the anchoring leg portion of the first fastener portion into the wall of second body vessel, advancing the second member to drive the anchoring leg portion of the second fastener portion into the wall of the first body vessel, and approximating the first member and the second member to approximate the anchoring leg portions of the first and second fastener portions with one another and to approximate the first and second body vessels with one another, wherein the fixing elements engage one another and inhibit separation of the first and second body vessels from one another.
It is envisioned that the anchoring leg portions can be biased to an expanded position and the fastener can be disposed within an insertion sleeve so as to maintain the fastener in a collapsed position. The method can further include the step of withdrawing the insertion sleeve so as to allow the anchoring leg portion to expand.
These and other features of the apparatus disclosed herein, will become apparent through reference to the following description of embodiments, the accompanying drawings and the claims.
BRIEF DESCRIPTION OF THE DRAWINGS
The accompanying drawings, which are incorporated in and constitute a part of this specification, illustrate embodiments of the disclosure and together with the detailed description of the embodiments given below, serve to explain the principles of the present disclosure.
FIG. 1 is a top plan view of a fastener, in accordance with an embodiment of the present disclosure, shown in a separated condition;
FIG. 2 is a side elevational view of the fastener of FIG. 1 ;
FIG. 3 is a top plan view the fastener of FIGS. 1-2 , shown in a coupled condition;
FIG. 4 is a side elevational view of the fastener of FIGS. 1-3 ;
FIG. 5 is an enlarged cross-sectional view of the indicated area of FIG. 3 ;
FIG. 6 is an enlarged end view of the fastener of FIGS. 1-5 ;
FIG. 7 is a cross-sectional side elevational view illustrating the positioning of the insertion tool and fastener into a hollow body organ;
FIG. 8 is a cross-sectional side elevational view illustrating the positioning of the insertion tool and the fastener as well as the expansion of the distal of the fastener in the hollow body organ in order to anchor the distal end of the fastener in the walls of the hollow body organ;
FIG. 9 is a cross-sectional side elevational view illustrating the expansion of the proximal end of the fastener in order to anchor the proximal end of the fastener to the walls of the body lumen;
FIG. 10 is a cross-sectional side elevational view illustrating the approximation of the hollow body organ to the body lumen;
FIG. 11 is a cross-sectional side elevational view illustrating the retraction of the insertion tool;
FIG. 12 is a cross-sectional side elevational view illustrating the final anastomosed hollow body organ and body lumen with the fastener anchored in position;
FIG. 13A is a side elevational view of a proximal leg of a fastener in accordance with an alternative embodiment of the present disclosure; and
FIG. 13B is a side elevational view of a distal leg of a fastener in accordance with the alternative embodiment of the present disclosure.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
Preferred embodiments of the presently disclosed anastomosis apparatus will now be described in detail with reference to the drawing figures wherein like reference numerals identify similar or identical elements. In the drawings and in the description which follows, the term “proximal”, as is traditional, will refer to the end of the surgical device or instrument of the present disclosure which is closest to the operator, while the term “distal” will refer to the end of the device or instrument which is furthest from the operator.
An anastomosis apparatus 100 , in accordance with an embodiment of the present disclosure, is shown in FIGS. 1-12 . Although anastomosis apparatus 100 offers significant advantages to a radical prostatectomy procedure, it will be understood that the device is applicable for use in any anastomotic procedure where two body vessels are to be brought together and joined.
As seen in FIGS. 1-6 , anastomosis apparatus 100 includes at least one fastener 102 and preferably a plurality of fasteners 102 radially disposed about a lumen 184 of an insertion sleeve 180 (see FIG. 7 ). Each fastener 102 includes a first fastener portion 104 and a second fastener portion 106 . First fastener portion 104 of fastener 102 includes a locking leg portion 108 and an anchoring leg portion 110 integrally formed with locking leg portion 108 . In particular, locking leg portion 108 includes a proximal end 112 and a distal end 114 from which anchoring leg portion 110 extends. Anchoring leg portion 110 includes a distal end 116 integrally coupled to distal end 114 of locking leg portion 108 and a sharpened proximal tip 118 . Desirably, sharpened proximal tip 118 of anchoring leg portion 110 is oriented towards proximal end 112 of locking leg portion 108 . Anchoring leg portion 110 has a first position “A” in which sharpened proximal tip 118 is spaced a distance from locking leg portion 108 and can be collapsed to a second position “C” (as seen in phantom in FIGS. 2 and 3 ) in which sharpened proximal tip 118 is in close proximity to locking leg portion 108 .
Preferably, locking leg portion 108 of first fastener portion 104 includes fixing elements for engaging second fastener portion 106 . The fixing elements in certain embodiments comprise a series of projections 120 formed along a side thereof and extending from proximal end 112 toward distal end 114 . First fastener portion 104 of fastener 102 further preferably includes a lip 122 projecting distally from distal end 110 of locking leg portion 108 .
Second fastener portion 106 of fasteners 102 includes a locking leg portion 124 and an anchoring leg portion 126 integrally formed with locking leg portion 124 . In particular, locking leg portion 124 includes a distal end 128 and a proximal end 130 from which anchoring leg portion 126 extends. Anchoring leg portion 126 includes a proximal end 132 integrally coupled to proximal end 130 of locking leg portion 124 and a sharpened distal tip 134 . Desirably, sharpened distal tip 134 of anchoring leg portion 126 is oriented towards distal end 128 of locking leg portion 124 . Anchoring leg portion 126 has a first position “A” in which sharpened distal tip 134 is spaced a distance from distal end 128 of locking leg portion 124 and can be collapsed to a second position “C” (as seen in phantom in FIGS. 2 and 4 ) in which sharpened distal tip 134 is in close proximity to locking leg portion 124 .
Preferably, locking leg portion 124 of second fastener portion 106 includes a locking passage 136 formed along a side surface thereof. As seen in FIG. 6 , locking passage 136 is defined by an upper wall 138 extending from an upper surface of locking leg portion 124 , a lower wall 140 extending from a lower surface of locking leg portion 124 and an interconnecting side wall 142 extending between the terminal ends of upper wall 138 and lower wall 140 . Locking passage 136 includes at least one, and desirably a plurality of fixing elements for engaging the fixing elements of the first fastener portion 104 . The locking passage 136 shown has fixing elements in the form of a plurality of projections 144 formed along an inner surface of interconnecting side wall 142 and oriented toward locking leg portion 124 . Locking passage 136 is sized and dimensioned to slidably receive end of first fastener portion 104 therethough. In particular, when locking leg portion 108 of first fastener portion 104 is inserted into locking passage 136 of second fastener portion 106 , projections 120 of locking leg portion 108 engage projections 144 of locking passage 136 to thereby effectively lock first fastener portion 104 of fastener 102 in position with respect to second fastener portion 106 of fastener 102 .
Similar to first fastener portion 104 of fastener 102 , second fastener portion 106 of fastener 102 includes a lip 148 projecting proximally from proximal end 130 of locking leg portion 124 .
As seen in FIG. 5 , it is contemplated that projections 120 of locking leg portion 108 and projections 144 of side wall 142 of locking passage 136 are teeth-like (e.g., saw toothed) projections 146 a , 146 b , respectively, configured and adapted to permit locking leg portion 108 to be inserted into locking passage 136 and hindering withdrawal of locking leg portion 108 therefrom. In particular, projections 146 a , 146 b are configured and adapted to permit locking leg portion 108 to slide in direction “D” while locking passage 136 is permitted to slide in direction “E”. However, once projections 146 a and projections 146 b engage one another, projections 146 a , 146 b prevent locking leg portion 108 from sliding in a direction opposite to direction “D” and prevent locking passage 136 from sliding in the direction opposite from “E”. In other words, projections 146 a , 146 b are configured and adapted to allow uni-directional movement of locking leg portion 108 relative to locking passage 136 and in turn unidirectional movement of first fastener portion 104 relative to second fastener portion 106 .
While projections 120 of locking leg portion 108 and locking passage 136 are shown and described as being formed along a side surface of first fastener portion 104 and second fastener portion 106 , respectively, it is envisioned and within the scope of the present disclosure that projections 120 can be provided along any surface of locking leg portion 108 of first fastener portion 104 and locking passage 136 can be provided along any surface of locking leg portion 124 of second fastener portion 106 .
First fastener portion 104 and second fastener portion 106 of fastener 102 can be made from any surgical grade material, such as stainless steel or titanium. It is envisioned that first and second fastener portions 104 , 106 are preferably made from a medical grade bio-absorbable material, such as, for example, polyglycolic acid (PGA) and/or polylactic acid (PLA). Preferably, the material and dimensions of fasteners 102 are selected such that fasteners 102 will dissolve after a predetermined period of time while retaining their structural integrity for a period of time sufficient to assure proper healing of the anastomosis site.
As seen in phantom in FIG. 7 , anastomosis apparatus 100 includes a first member or anvil 150 , a second member or pusher 170 , and a shaft 190 for mounting the fasteners 102 in an insertion sleeve 180 . The anvil 150 and pusher 170 are shown in phantom in FIGS. 3 and 4 . Anvil 150 includes an elongate body portion 152 and a hook 154 formed at a distal end 156 thereof. Hook 154 of anvil 150 is configured and adapted to engage lip 120 of first fastener portion 104 of fastener 102 . Pusher 170 includes an elongate body portion 172 and a recess 174 formed at a distal end 176 thereof. Recess 174 of pusher 170 is configured and adapted to engage lip 146 of second fastener portion 106 of fastener 102 .
As seen in FIGS. 7-11 , insertion sleeve 180 includes a distal end 182 , a proximal end (not shown) and defines a lumen 184 extending therethrough which defines a central axis. Shaft 190 is configured and adapted to be slidably received in lumen 184 of insertion sleeve 180 . It is envisioned that shaft 190 include a plurality of radially oriented longitudinally extending grooves (not shown) formed therein. Accordingly, each groove of shaft 190 can be configured and adapted to receive a respective anvil 150 , pusher 170 and fastener 102 . Preferably, shaft 190 is sized such that when shaft 190 is inserted into sleeve 180 , anchoring leg portion 108 of first fastener portion 104 and anchoring leg portion 124 of second fastener portion 106 are in the second position “C” (see FIG. 7 ).
Anvil 150 and pusher 170 are arranged with respect to one another so as to form a recess for receiving fastener 102 between hook 154 and recess 174 . Fastener 102 is disposed in the recess so that first fastener portion 104 and second fastener portion 106 are engaged with one another, leaving room for advancing the anchoring leg portions toward one another. A plurality of fasteners 102 are disposed in insertion sleeve 180 , with the shaft 190 disposed between the fasteners 102 and their corresponding anvil and pusher. (see FIG. 7 ).
A preferred method of use and operation of anastomosis apparatus 100 in performing a radical prostatectomy anastomosis will now be described in greater detail with reference to FIGS. 1-12 and in particular with reference to FIGS. 7-12 . Anastomosis apparatus 100 can be used in either the retropubic or the perineal prostatectomy approaches, or any approach in which the bladder and urethra must be approximated. With the prostate removed, the bladder neck “N” of the bladder “B” is first reconstructed by everting the inner mucosal lining of bladder “B” and suturing it down to the outer wall of bladder “B”, using known surgical techniques. Likewise, urethral stump “S” of urethra “U” is reconstructed by everting the inner mucosal lining of urethral stump “S” and suturing it down to the outer wall of urethra “U”, using known surgical techniques.
Preferably, with bladder neck “N” reconstructed, bladder neck “N” is sized to properly accommodate and retain distal end 180 of sleeve 180 within bladder “B” using a standard tennis racket type closure (i.e., the opening of the bladder neck constituting the head of the tennis racket and a radial incision extending from the bladder neck constituting the handle portion of the tennis racket). The size of the bladder neck will vary depending on the patient. Typically, the bladder neck “N” is sized to be approximately 7-8 mm in diameter.
With bladder neck “N” reconstructed, apparatus 100 is passed trans-urethrally through urethra “U” until distal end 182 of insertion sleeve 180 extends out of urethral stump “S” and into bladder “B” through bladder neck “N”, as seen in FIG. 7 .
With apparatus 100 so positioned, insertion sleeve 180 is withdrawn in a proximal direction to expose sharpened proximal tips 118 of first fastener portions 104 . The anchoring leg portions 110 are biased to the first position “A” so that when sharpened proximal tips 118 are exposed from within insertion sleeve 180 , anchoring leg portions 110 of first fastener portions 104 are deployed to the first position “A”. (see FIG. 8 ). With anchoring leg portions 110 deployed, hooks 154 of anvils 150 are withdrawn in a proximal direction to engage lips 122 of first fastener portions 104 and to drive sharpened proximal tips 118 through the wall of bladder “B”, see FIG. 9 .
As seen in FIG. 9 , insertion sleeve 180 is further withdrawn in a proximal direction until sharpened distal tips 134 and anchoring leg portion 126 of second fastener portion 106 are exposed. The anchoring leg portions 126 are biased to the first position “A” so that when anchoring leg portions 126 are completely exposed from within insertion sleeve 180 , anchoring leg portions 126 of second fastener portions 106 are deployed to first position “A”. (see FIG. 9 ). With anchoring leg portions 126 deployed, pushers 170 are advanced in, a distal direction to engage lips 148 and to drive sharpened distal tips 134 through the wall of urethral stump “S”.
With sharpened proximal tips 118 of first fastener portions 104 penetrating the wall of bladder “B” and with sharpened distal tips 134 penetrating the wall of urethral stump “S”, hooks 154 of anvils 150 are approximated toward recesses 174 of pushers 170 to thereby approximate anchoring leg portions 110 of first fastener portion 104 and anchoring leg portions 126 of second fastener portion 106 towards one another. Concomitantly, as anchor leg portions 110 and 126 are approximated towards one another bladder neck “N” is approximated towards urethral stump “S”. (see FIG. 10 ). In accordance with the present disclosure, approximation of anchor legs 110 and 126 towards one another results in projections 120 and 144 incrementally engaging one another and maintaining the position of anchor leg 110 relative to anchor leg 126 . Accordingly, projections 120 and 144 prevent bladder “B” from separating from urethra “U”.
After bladder neck “N” has been approximated toward urethral stump “S”, pushers 170 and shaft 190 are withdrawn from insertion sleeve 180 and anvils 150 unhooked from lips 122 . (see FIG. 11 ). Thereafter, anvils 150 and insertion sleeve 180 are withdrawn from urethra “U”.
An alternate embodiment of a fastener 200 , in accordance with the present disclosure, is shown in FIGS. 13A and 13B . Unlike fastener 102 from above, fastener 200 includes a first fastener portion 202 and a second fastener portion 204 . First fastener portion 202 includes a locking leg portion 206 and an anchoring leg portion 208 pivotally coupled to a proximal end of locking leg portion 206 . In the embodiment shown, anchoring leg portion 208 is pivotally coupled to locking leg portion 206 by a pivot pin 210 , but other means known in the art may also be used. Alternatively, locking leg portion 206 or anchoring leg portion 208 can be provided with an integrally formed pin that extends outwardly for receipt in an aperture formed in the other of locking leg portion 206 or anchoring leg portion 208 . First fastener portion 202 includes a suture 212 connected to anchoring leg portion 208 for pulling on anchoring leg portion 208 and lifting a distal end of anchoring leg portion 208 away from locking leg portion 206 (e.g., from first position “A” to second position “C”). It is contemplated that the proximal end of locking leg portion 206 includes a stop (not shown) for stopping the lifting of anchoring leg portion 208 beyond a predetermined amount.
As seen in FIG. 13B , second fastener portion 204 includes a locking leg portion 214 and an anchoring leg portion 216 pivotally coupled to a distal end of locking leg portion 214 by a pivot pin 218 . Alternatively, locking leg portion 214 or anchoring leg portion 216 can be provided with an integrally formed pin and extending outwardly for receipt in an aperture formed in the other of locking leg portion 214 or anchoring leg portion 216 . Second fastener portion 204 further includes a suture 220 connected to anchoring leg portion 216 , extending around the distal end of locking leg portion 214 , for pulling on anchoring leg portion 216 and lifting a proximal end of anchoring leg portion 216 away from locking leg portion 214 (e.g., from first position “A” to second position “C”). It is contemplated that the distal end of locking leg portion 214 includes a stop (not shown) for stopping the lifting of anchoring leg portion 216 beyond a predetermined amount.
While apparatus in accordance with the present disclosure have been described as being used in connection with a radical prostatectomy procedure, it is envisioned that apparatus having similar structures and modes of operation can be used in various other surgical procedures. It will be understood that various modifications may be made to the embodiments of the presently disclosed anastomosis device and method disclosed herein. For example, one or more fasteners may be arranged in the insertion sleeve. In further embodiments, the insertion sleeve is sized to accommodate the fastener without requiring the anchoring leg portions to collapse to position “C”. The fastener may comprise a single part with a corrugated, hinged or collapsible portion. The fasteners, in certain embodiments, comprise a fixing element comprising a separate part.
Therefore, the above description should not be construed as limiting, but merely as an exemplification of a preferred embodiment. Those skilled in the art will envision other modifications within the scope of the present disclosure. | Apparatus and methods for performing a surgical anastomotic procedure are disclosed herein. Apparatus according to the present disclosure include at least one fastener including a first fastener portion having an anchoring leg portion, a second fastener portion including an anchoring leg portion, wherein the first and second fastener portions are operatively associated with one another to selectively fix the position of the first fastener portion relative to the second fastener portion. The apparatus has a first member for engaging the first fastener portion and a second member for engaging the second fastener portion. The first member and the second member are movable with respect to one another to move the first fastener portion and second fastener portion with respect to one another. | 0 |
CROSS-REFERENCES TO RELATED APPLICATIONS
[0001] This application claims the benefit of U.S. Provisional Application No. 60/555,628 (Attorney docket No. 020859-005500US; Client Ref. CIT-4060-P), filed Mar. 23, 2004, the disclosure of which is incorporated herein by reference in its entirety.
BACKGROUND OF THE INVENTION
[0002] The present invention relates generally to optical probes and more particularly to optical probes for use with Optical Coherence Tomography (OCT) and other optical imaging modalities.
[0003] OCT is a laser based imaging modality that uses near infrared or infrared laser light to non-destructively image subsurface tissue structures. An imaging depth on the order of millimeters (mm), with a spatial resolution of a few micrometers (μm) is relatively easily achieved using OCT at practical light fluence levels on the order of 100 μW. OCT is therefore very useful for in vitro and in vivo tissue structure imaging applications such as may be used during minimally invasive surgical procedures. Currently, both side-imaging endoscope systems and forward imaging endoscope systems are known.
[0004] The construction of a needle endoscope that is capable of performing forward OCT imaging presents very significant design challenges. Current endoscopes are typically more than 5 mm thick. The thickness of such probes, especially when compared with their en face imaging area, e.g., about 2 mm wide, makes them undesirable as a needle endoscope for image-guided surgical procedures. One major challenge of making a thin endoscope lies with the difficulty of designing a probe beam deflection system that is capable of covering a sufficient scan volume while constraining the probe diameter to be less than about 2 mm to minimize the invasiveness of the probe. A reasonable OCT scan volume for providing sufficient image information would be a conical volume that is about 3 mm in length and about 2 mm in diameter at its maximum circumference.
[0005] Therefore it is desirable to provide probes such as forward imaging endoscope needles useful for OCT imaging of a scan volume that overcome the above and other problems.
BRIEF SUMMARY OF THE INVENTION
[0006] The present invention provides forward imaging optical endoscope probes useful in imaging applications, and in particular in imaging applications using OCT as the imaging modality. The endoscope probes of the present invention advantageously allow for improved high-resolution imaging of non-transparent tissue structures in the immediate vicinity of the endoscope needle tip.
[0007] According to the present invention, a probe includes an optical fiber having a proximal end and a distal end and defining an axis, with the proximal end of the optical fiber being proximate a light source, and the distal end having a first angled surface. A refractive lens element is positioned proximate the distal end of the optical fiber. The lens element and the angled fiber end are both configured to separately rotate about the axis so as to image a conical scan volume when light is provided by the source. Reflected light from a sample under investigation is collected by the fiber and analyzed by an imaging system. Such probes may be very compact, e.g., having a diameter 1 mm or less, and are advantageous for use in minimally invasive surgical procedures.
[0008] According to one aspect of the present invention, an optical apparatus is provided that typically includes an optical fiber including a proximal end and a distal end and defining an axis, wherein the proximal end of the optical fiber is proximate a light source, and wherein the distal end comprises a first angled surface. The apparatus also typically includes a refractive lens element proximate the distal end of the optical fiber, wherein the lens element and the optical fiber are both configured to rotate about the axis, and wherein the optical fiber and the lens are configured to rotate relative to each other about the axis.
[0009] According to another aspect of the present invention, an optical apparatus is provided that typically includes an optical fiber having a proximal end and a distal end and defining an axis, wherein the proximal end of the optical fiber is proximate a light source, and wherein the distal end is proximal a first refractive lens element. The apparatus also typically includes a second refractive lens element proximate the first lens element, wherein the second lens element is configured to rotate about the axis, and wherein the first lens element is configured to rotate about the axis separate from the second lens element.
[0010] According to yet another aspect of the present invention, a method is provided for imaging a forward scan volume of a tissue sample using a forward scanning probe that typically includes an optical fiber including a proximal end and a distal end and defining an axis, wherein the proximal end of the optical fiber is proximate a light source, and wherein the distal end is proximal a first refractive lens element. The probe further typically includes an imaging end having a second refractive lens element positioned proximate the first lens element, wherein the second lens element is configured to rotate about the axis, and wherein the first lens element is configured to rotate about the axis separate from the second lens element. The method typically includes positioning the imaging end of the probe proximal a tissue sample to be imaged, providing a light beam to the proximal fiber end from the light source, rotating the inner tube at a first rate, and simultaneously rotating the outer tube at a second rate different from the first rate so as to image a conical scan volume of the tissue sample.
[0011] Reference to the remaining portions of the specification, including the drawings and claims, will realize other features and advantages of the present invention. Further features and advantages of the present invention, as well as the structure and operation of various embodiments of the present invention, are described in detail below with respect to the accompanying drawings. In the drawings, like reference numbers indicate identical or functionally similar elements.
BRIEF DESCRIPTION OF THE DRAWINGS
[0012] FIG. 1 illustrates a side view of a probe design including a fiber and a lens element according to one embodiment.
[0013] FIG. 2 illustrates a side view of a lens element design according to one embodiment.
[0014] FIG. 3 illustrates another embodiment of a lens element design.
[0015] FIG. 4 illustrates an orientation of the elements of FIG. 1 that results in a maximum angle of the forward light beam with respect to the forward axis.
[0016] FIG. 5 a illustrates a side view of a probe design according to another embodiment of the present invention.
[0017] FIG. 5 b illustrates an orientation of the elements of FIG. 5 a that results in a zero angle of the forward light beam with respect to the forward axis.
[0018] FIG. 5 c illustrates a rotation actuation system according to one embodiment.
DETAILED DESCRIPTION OF THE INVENTION
[0019] The present invention provides novel probes, and systems and methods for optically scanning a conical volume in front of a probe, for use with an imaging modality, such as Optical Coherence Tomography (OCT). Other useful imaging modalities for which probes of the present invention are useful include Optical Doppler Tomography (ODT), and Speckle Decorrelation Tomography (SDT).
[0020] A probe 10 according to one embodiment is shown in FIG. 1 . As shown, probe 10 includes an optical fiber 20 and a lens element 30 proximal the end of fiber 20 . A tube 40 encloses fiber 20 . Tube 40 is also coupled to lens element 30 to facilitate rotation of lens element 30 relative to fiber 20 . Fiber 20 may itself be rotated separately from tube 40 , in one aspect, as will be described in more detail below with reference to FIG. 5 .
[0021] In one aspect, fiber 20 includes a single mode fiber (although multimode fibers can be used if desired) having an end that is angled cut at an angle of θ as shown in FIG. 1 . Input light from a light source (not shown) positioned proximal a distal end of fiber 20 enters fiber 20 and exits at the end of fiber 20 proximal lens element 30 . The light exiting from the fiber 20 will be incident on focusing lens element 30 . In one aspect, it is preferred that the light source provides collimated light in the infrared (IR) or near-IR wavelength range. Of course, other wavelengths may be used as desired. One example of a useful light source is a laser or a diode laser that emits in the IR or near-IR wavelength range. FIGS. 2 and 3 show examples of two possible ways the focusing lens element 30 may be constructed.
[0022] According to one embodiment, as shown in FIG. 2 , lens element 30 includes a (cylindrical) GRIN lens 31 that is cut and polished at one end to have an angle of θ 1 . The angle θ 1 is chosen so that when the GRIN lens 31 and the end of fiber 20 are oriented in the manner shown in FIG. 1 , the exiting light beam from the GRIN lens 31 is focused in the forward direction. In one aspect, therefore, the angle θ 1 should be substantially close (e.g., within 1° or 2°) to θ, the angle at the fiber end.
[0023] According to another embodiment, as shown in FIG. 3 , lens element 30 includes a (cylindrical) GRIN lens 32 and an angled glass wedge element 34 attached to the GRIN lens 32 . Wedge element 34 is preferably formed (e.g., cut and polished) from a cylindrical glass element. Wedge element 34 may be glued or otherwise secured to GRIN lens 32 . The choice of angle cut presented by the wedge 34 is determined by the same considerations as described above. For example, the angle θ 1 should be substantially close (e.g., within 1° or 2°) to θ, the angle at the fiber end.
[0024] In one aspect, rotation of the GRIN lens element 30 shown in FIG. 2 (or the GRIN-wedge construction shown in FIG. 3 ) with respect to a fixed fiber orientation will vary the angle of the forward light beam from zero degrees to a certain angle with respect to the forward axis. Zero angle is achieved when the two elements are oriented as shown in FIG. 1 . The maximum angle is achieved when the two elements are oriented as shown in FIG. 4 . A visualization of the zero angle and maximum angle can be seen in FIG. 5 b and 5 a , respectively, which illustrate a slightly different probe configuration. The continuous rotation of the lens element 30 between those two orientations will complete a span of the angle between the zero angle and maximum angle values. Therefore, in one aspect, rotation of both elements will allow for a conical scan volume to be imaged. For example, rotating the fiber 20 at one rate and the GRIN lens 30 of FIG. 2 (or GRIN-wedge construction of FIG. 3 ) at a different rate allows for a forward conical scan volume to be taken.
[0025] The focal length of the lens element 30 and the distance from the tip of fiber 20 is preferably selected so that the output light forms a focus at an appropriate desired distance in the foreground. For example, in an OCT imaging system, the focal point can be chosen to be at half the penetration depth of the OCT imaging capability. A useful focus length for many applications is about 2.0 mm, however, it should be understood that a focal length of between about 0.1 mm and about 10 mm or more can be implemented.
[0026] FIG. 5 illustrates a probe 110 , and a probe scan system, according to another embodiment of the present invention. In the embodiment shown, optical probe 110 includes a pair of GRIN lenses and a pair of cylindrical glass elements that are cut at an appropriate angle θ. As shown, probe 110 includes an optical fiber 120 and a fiber lens element 125 proximal the end of fiber 120 . A first tube 140 (“inner tube”) encloses fiber 120 . Inner tube 140 is also coupled to fiber lens element 125 to facilitate rotation of lens element 125 . A second rotatable tube 150 (“outer tube”) encloses tube 140 and refractive lens element 130 to facilitate rotation of lens element 130 relative to fiber lens element 125 . Input light from a light source (not shown) at a distal end of fiber 120 enters fiber 120 and exits the fiber end internal to inner tube 140 as shown. In one aspect, the optical fiber 120 is fixed at the focal point of fiber lens element 125 within the inner tube. In preferred aspects, lens element 125 includes a GRIN lens. The GRIN lens may be cut at an angle or it may be coupled with an angled wedge element (e.g., similar to wedge 34 discussed above with reference to FIG. 3 ) as shown. In this case, the light output is collimated by the GRIN lens and angularly displaced by the angled glass wedge element. The tilted beam is brought to a focus by lens element 130 , which in one aspect as shown includes a second glass wedge element and GRIN lens pair, and which is attached to the outer tube.
[0027] The rotation of lens element 130 with respect to fiber lens element 125 will change the angle of the forward light beam with respect to the forward axis. For example, FIG. 5 a shows the orientations that provide a maximum angle, and FIG. 5 b show the orientations that provide a zero angle. If the angular difference between the orientation of the first and second angled surfaces is given by Δφ (Δφ=0 when the cylinders are oriented as shown in FIG. 5 b ), the angle made by the output beam to the forward axis is approximately given by:
ψ≈θ{square root}{square root over (( n −1) 2 (1−cos(Δφ) 2 )+sin(Δφ) 2 )} (6)
where n is the refractive index of the cylinders. By rotating fiber lens element 125 with respect to lens element 130 , the angle ψ made by the output beam relative to the forward axis can be changed from 0 to 2(n−1) rads. Rotating both lens elements in synchrony scans the output beam in a complete circular cone. If the focal point of the output is 2 mm from the probe tip and it is desirable to cover a scan area 2 mm in diameter at that distance, the angular cut, θ, should be about 0.19 rads (about 11°). Given the smallness of the angle, in one aspect, the design is further simplified by simply cutting the GRIN lenses with the given angular tilt, eliminating the need for glass wedge elements.
[0028] In one embodiment, the outer and inner tubes (holding lens element 130 and fiber 120 , respectively) are preferably mounted to two different motors via gears as shown in FIG. 5 c . In the embodiment of FIG. 1 , tube 40 and fiber 20 may similarly be coupled to different motors. In both cases, the complete rotation of the refractive lens element and the fiber end with respect to a reference plane will complete a conical sweep. Therefore, the combination of these two motions will create a scan volume equal to a solid cone with a maximum angle from the forward axis given by the considerations described above. Each motor preferable provides one or multiple rotational speeds in the range of a fraction of a HZ to about 1 KHz or more. Also, each motor may rotate the coupled elements in the same or opposite direction as the other motor. Further, the fiber 120 need not rotate with the fiber lens element 125 ; that is inner tube may rotate without rotation of fiber 120 . It should also be appreciated that a single motor may be used to rotate both the inner and outer tubes. In this case, a ratchet and pawl type mechanism coupling the motor to both tubes may be used to rotate the tubes at different rotational speeds. Examples of a similar rotation actuation system and a fiber connection to an OCT imaging system for a side scanning probe is shown in “Scanning single-mode fiber optic catheter-endoscope for optical coherence tomography”, Optics Letters, V21, pg. 543 (1996), which is hereby incorporated by reference.
[0029] By using OCT imaging to create depth resolved imaging along each light beam path orientation, a three dimensional image of the structure in front of the imaging needle (probe) can be constructed. For example, an imaging Fourier Domain OCT (FDOCT) engine can be used with the probes of the present invention to acquire tomographic images of the forward scan volume. Given the large forward scan volumes possible (e.g., about 3-4 mm forward and an area of diameter 4 mm at the 4 mm forward distance point), a needle endoscope according to the present invention provides unprecedented forward imaging capability. For example, by rotating the inner tube at 100 Hz and the outer tube at 1 Hz, a 3 dimensional image with a total of 10 8 voxel per second can be generated with an OCT imaging system that is capable of acquiring 100 kHz rate A-scans with 1,000 pixels each.
[0030] This innovative and yet elegantly simple design enables very compact probes to be built, e.g., probes of diameter 1 mm or less (e.g., 500 microns or less). Such devices provide a dramatic improvement over existing endoscopic imaging technology. The compact size and forward tomographic imaging capability of the probes of the present invention make image guidance of minimally invasive surgical procedure possible.
[0031] While the invention has been described by way of example and in terms of the specific embodiments, it is to be understood that the invention is not limited to the disclosed embodiments. To the contrary, it is intended to cover various modifications and similar arrangements as would be apparent to those skilled in the art. For example, rather than having a flat end face, a GRIN lens may be angled cut and a wedge element may be attached thereto and cut so as to provide the desired angled surface, e.g., θ or θ 1 . Additionally, the tubes holding the lens elements and fibers may comprise a flexible or rigid material. Therefore, the scope of the appended claims should be accorded the broadest interpretation so as to encompass all such modifications and similar arrangements. | Probes, and systems and methods for optically scanning a conical volume in front of a probe, for use with an imaging modality, such as Optical Coherence Tomography (OCT). A probe includes an optical fiber having a proximal end and a distal end and defining an axis, with the proximal end of the optical fiber being proximate a light source, and the distal end having a first angled surface. A refractive lens element is positioned proximate the distal end of the optical fiber. The lens element and the fiber end are both configured to separately rotate about the axis so as to image a conical scan volume when light is provided by the source. Reflected light from a sample under investigation is collected by the fiber and analyzed by an imaging system. Such probes may be very compact, e.g., having a diameter 1 mm or less, and are advantageous for use in minimally invasive surgical procedures. | 0 |
FIELD OF THE INVENTION
[0001] The invention relates to the field of thin illuminating panels which may be in the form of a portion of a wall, ceiling or rigid or semi-rigid partition.
[0002] The invention relates more especially to an illuminating complex which is capable, in particular, of being fitted in a building or motor vehicle intended for transporting passengers such as a train or aircraft.
DESCRIPTION OF THE PRIOR ART
[0003] Generally speaking, illuminating panels fitted into a partition comprise light sources such as fluorescent lamps concealed behind a light diffuser sheet made of frosted glass or polymethyl methacrylate (PMMA).
[0004] However, the fluorescent lamps must be fitted some distance away from the sheet in order to remain invisible through the diffuser sheet. Such panels are therefore fairly bulky at the rear of the diffuser sheet. They must also have a rear panel which is used solely to support the various electrical power supply units for the fluorescent lamps. Such panels are therefore thick and heavy.
[0005] Textile webs which comprise woven optical fibres with binding yarns that are kept tensioned by a rigid frame are also known. The woven fabrics thus formed are then treated in various ways in order to obtain uniform lateral light emission.
[0006] However, such webs cannot be arranged in direct contact with a partition. In addition, they have relatively little resistance to tearing and fire. They must therefore be installed in spaces which are protected against these various hazards.
[0007] Illuminating panels made of a non-woven web of optical fibres sandwiched between a transparent front sheet and a light reflecting rear sheet are also known. Such light sources are described, in particular, in U.S. Pat. No. 5,021,928.
[0008] Nevertheless, using a non-woven web of optical fibres poses numerous problems in terms of maintaining a uniform surface appearance when handling it before fitting it between the two sheets and when subsequently connecting the optical fibres to one or more light sources.
[0009] Not only that, the transparent front sheet has the drawback of substantially increasing the weight of the illuminating complex. The cost of manufacturing such an illuminating complex is consequently correspondingly expensive. What is more, such an illuminating panel does not make it possible to retain the special touch and feel of textiles.
SUMMARY OF THE INVENTION
[0010] The invention relates to an illuminating complex comprising a light source having a textile web incorporating optical fibres in the warp and/or weft directions, said fibres being associated with binding yarns and said optical fibres being capable of emitting light laterally.
[0011] It is characterised in that the textile web is attached to a rigid or semi-rigid backing and in that a bonding intermediate allows the textile web to be at least partly attached in an irreversible manner to the rigid backing.
[0012] In other words, there is no air in the gap between the textile web and the rigid backing, thus improving thermal conductivity and heat dissipation. The combination of a small quantity of available oxygen, significant heat dissipation and also the high thermal resistance of the rigid backing creates a barrier effect. Such an illuminating complex can therefore be extremely fire resistant. Surprisingly, an illuminating complex which incorporates a textile web is much more fire resistant than the textile web on its own.
[0013] The bonding intermediate is chosen in order to make sure that the entire complex does not release toxic or opaque smoke and that it achieves a satisfactory classification in classification in so-called smoke tests. Like the rigid backing, the bonding intermediate can create a barrier effect which affords protection against mechanical stresses.
[0014] The textile web is bonded on a rigid or semi-rigid backing in those areas which are visible and provide illumination. In fact, in areas which are not visible, especially the edge of the web, the optical fibres must be connected to one or more light sources Consequently, the textile web is not directly attached to the rigid backing in such areas. This connection area may, depending on the particular variant, be located in the same plane as the textile web or be located to the rear of this plane, behind the rigid backing.
[0015] The bonding intermediate is selected so as to enable a user to touch the woven fabric comprising the optical fibres directly without making it possible to damage or even pull the optical fibres out.
[0016] Also, the illuminating complex thus formed has a thickness of several millimetres and can assume any kind of flat or warped shape. To achieve this, the rigid backing may, in particular, be folded or stamped by a press.
[0017] In one particular embodiment, the optical fibres can be woven with binding yarns. In other words, the binding yarns are woven in the warp and/or weft direction whereas the optical fibres are woven in the weft and/or warp direction on a loom.
[0018] Advantageously, the textile web may incorporate ground threads woven in the warp and weft directions as a plain weave.
[0019] In other words, each weft ground thread passes alternately under then over a warp thread. Such a weave makes it possible to ensure optimum mechanical cohesion of the woven fabric while encouraging good light transmission. The binding yarns are therefore woven with the ground threads.
[0020] In practice, the optical fibres can be locally attached to the ground threads by means of binding yarns with the optical fibres being positioned substantially in a plane which is parallel to the plane defined by the weave of the ground threads.
[0021] This way, the optical fibres can be held in position parallel to each other thanks to the binding yarns which are periodically woven, but not alternately woven, with the optical fibres. This type of complex bonding of binding yarns with the optical fibres is made possible in particular by a Jacquard-loom which allows individual selection of every warp thread and weft thread at any point on the woven fabric. For example, the period which separates two loops of the weave which successively cover a single optical fibre may comprise approximately ten loops of the ground threads of the weave.
[0022] In a first embodiment, the optical fibres can be in continuous contact with the bonding intermediate.
[0023] The optical fibres are thus immobilised relative to the rigid backing. The binding yarns then cover the optical fibres and protect them against external environmental stresses.
[0024] In addition, the presence of the optical diopter between the optical fibres and the bonding intermediate allows direct reflection of a significant quantity of luminous energy, thus increasing the intensity of the lateral illumination produced by the complex.
[0025] In this case, the binding yarns can be in substantially point contact with the bonding intermediate.
[0026] This way, the binding yarns have translational mobility parallel to the surface defined by the rigid backing. This arrangement makes it possible to increase tear resistance and improve the protection of the optical fibres by the binding yarns.
[0027] Also, in order to allow maximum light transmission, the weave formed by the binding yarns can be breathable. For example, the distance between two successive binding yarns in the weft or warp directions can exceed two thirds of the diameter of these binding yarns, whereas the diameter of the binding yarns is less than the radius of the optical fibres.
[0028] In a first embodiment, the binding yarns can be in substantially continuous contact with the bonding intermediate.
[0029] In this case, the optical fibres provide direct lateral illumination without being masked by the binding yarns. Such an arrangement allows maximum luminous energy transmission.
[0030] In contrast to the first embodiment, the binding yarns can then be very tightly spaced so as to form a screen which makes it possible to reflect light.
[0031] Advantageously, the illuminating complex may comprise an attached protective layer which faces the optical fibres.
[0032] In other words, for certain particular applications which demand a high level of protection, one can position a protective layer close to or even in contact with the optical fibres, this protective layer preferably being transparent or translucent in order to let as much light through as possible. This protective layer may consist of a breathable material such as a woven fabric, mesh, netting or tulle or, more generally speaking, even a non-woven fabric. The protective layer can then be attached to the optical fibres by another bonding intermediate. Such a transparent protective layer can, in particular, be formed by a sheet of glass, polymethyl methacrylate (PMMA) or polycarbonate (PC).
[0033] In another variant, the protective layer can also be obtained by subjecting the illuminating complex to a surface treatment, in particular a process involving coating, spraying or polymerisation, especially a process of the resin or gel coat type.
[0034] In practice, the rigid backing may comprise a reflecting surface to which the bonding intermediate is attached.
[0035] In other words, the reflecting surface is used to reflect and diffuse light towards the fabric-side of the woven fabric. This reflecting surface is advantageously coloured white but may be made according to various embodiments as an independent element or be the actual backing itself if the latter is coloured white in the mass, for instance a polycarbonate sheet.
[0036] In one particular embodiment, the reflecting surface can be attached to the rigid backing.
[0037] In fact, this reflecting surface can also consist of a paint film, an anodised metallic layer, a pressure-sensitive adhesive film or even foam or a white-coloured textile.
[0038] Also, the rigid backing can be made of a material chosen from a group comprising metals, polymers and composites.
[0039] Such materials are actually light and very rigid. These materials also make it possible to give the illuminating complex considerable resistance to heat or fire and ensure it dissipates stored heat very quickly. These materials offer good thermal conductivity.
[0040] Advantageously, the optical fibres can each be formed by a core clad in a fluorinated polymer.
[0041] In practice, the core of the optical fibres can be made of a material chosen from a group comprising polymethyl methacrylate (PMMA) and polycarbonate (PC).
[0042] In one particular embodiment, the ground threads can be made of a material chosen from a group comprising natural, synthetic or artificial yarns or fibres, especially wool, aramide, polyamide, chlorofibres, polyester and cotton.
[0043] Thus, the optical fibres can be woven with binding yarns which have good resistance to fire and mechanical stresses alike. Such yarns include, in particular, those marketed under the Trevira®, Nomex® and Kermel® brand names or combinations of these yarns with other textile yarns in order to give the textile thus formed other properties or to reduce its overall cost.
[0044] In addition, the bonding intermediate can be white in colour and contribute towards reflection. In another embodiment, the bonding intermediate can also be transparent.
[0045] Preferably, positioning the bonding intermediate on the rigid and sometimes curved surfaces can be made easier if the latter is in the form of a double-sided cold-rollable adhesive or by using a sprayed liquid adhesive.
[0046] This bonding intermediate can also contribute towards the barrier effect already produced by the rigid backing and is consequently heat resistant. Finally, it is preferably free of toxic elements capable of modifying the “smoke” classification of the complex.
BRIEF DESCRIPTION OF THE DRAWINGS
[0047] In order that the way in which the invention is implemented and its resulting advantages may more readily be understood, the following description of an embodiment is given, merely by way of example, reference being made to the accompanying drawings.
[0048] FIG. 1 is a perspective view of the location of a textile web before it is incorporated in an illuminating complex in accordance with the invention;
[0049] FIG. 2 is a front view of the back of such a textile web;
[0050] FIGS. 3 and 4 are cross-sectional views of two alternative ways of positioning the textile web on a rigid backing.
DETAILED DESCRIPTION OF THE INVENTION
[0051] As stated above, the invention relates to an illuminating complex made up of a textile web which incorporates optical fibres arranged in the warp or weft directions and woven with binding yarns.
[0052] As shown in FIG. 1 , the illuminating complex comprises a textile web ( 2 ) in which the optical fibres ( 3 ) are woven with binding yarns ( 4 ). Depending on the particular embodiment, the optical fibres ( 3 ) or the binding yarns ( 4 ) can be arranged either in the warp or the weft direction. In the case shown, binding yarns ( 4 ) are positioned both in the warp and weft directions, whereas the optical fibres ( 3 ) are arranged either in the weft direction or the warp direction.
[0053] Also and in order to improve the lighting characteristics of the illuminating complex which incorporates such a textile web ( 2 ), binding yarns ( 4 ) can be locally woven with the optical fibres ( 3 ). The binding yarns ( 4 ) can be interwoven as a “fabric” type weave in order to create empty gaps capable of letting through the luminous energy emitted by the optical fibres ( 3 ). With this particular arrangement, optical fibres ( 3 ) are then arranged substantially in a plane which is parallel to that defined by the binding yarns ( 4 ).
[0054] As shown in FIG. 2 , the cross section of optical fibres ( 3 ) can exceed that of binding yarns ( 4 ) in order to allow transfer of luminous energy at the level of the rear panel of the fabric defined by the binding yarns ( 4 ). For instance, optical fibres ( 3 ) can have a diameter which is twice that of binding yarns ( 4 ).
[0055] What is more, in order to let as much light as possible through the weave formed by binding yarns ( 4 ), they can, for instance, be spaced apart a distance which exceeds two thirds of the diameter of the binding yarns ( 4 ).
[0056] The textile web ( 2 ) thus formed is then attached to a rigid backing and bonded by means of a bonding intermediate. It is also possible to arrange the textile web facing the rigid backing with its fabric-side and back faces as shown in FIGS. 3 and 4 .
[0057] This way, and as shown in FIG. 3 , the illuminating complex is formed by a textile web ( 2 ) the fabric-side face of which cooperates with bonding intermediate ( 6 ). In this case, optical fibres ( 3 ) are in continuous contact with bonding intermediate ( 6 ). This bonding intermediate ( 6 ) also allows direct reflection of the light emitted by optical fibres ( 3 ) in a direction which is opposite to that of rigid backing ( 5 ).
[0058] Illuminating complex ( 1 ) may nevertheless comprise a reflecting surface ( 8 ) which can either be attached to rigid backing ( 5 ) or be formed directly by this backing ( 5 ) if the latter is made, in particular, as a polycarbonate sheet coloured white in the mass or even even an anodised aluminium sheet.
[0059] The binding yarns ( 4 ) can then be used to protect the illuminating elements formed by optical fibres ( 3 ). They also make it possible to give the illuminating complex ( 1 ) the distinctive touch and feel of a textile material.
[0060] As shown in FIG. 4 , illuminating complex ( 11 ) may comprise a textile web ( 12 ) attached by its back to a rigid backing ( 15 ). Bonding intermediate ( 16 ) is then used to attach binding yarns ( 14 ) to rigid backing ( 15 ). Optical fibres ( 13 ) can then emit light radially in a direction which is opposite to that of rigid backing ( 15 ) and bonding intermediate ( 16 ) without being masked by a weave formed by binding yarns ( 14 ).
[0061] For certain applications, in particular in order to prevent physical damage to optical fibres ( 13 ), a protective layer ( 17 ) can be attached facing optical fibres ( 13 ). This protective layer ( 17 ) can assume various forms and, in a first embodiment, is in the form of a breathable textile in order to give a textile touch and feel to the illuminating complex ( 11 ) while letting as much light as possible through the openings in the textile.
[0062] In a second embodiment, protective layer ( 17 ) can also be made of a solid transparent material and be in the form of a rigid sheet made of a material such as glass, PMMA or polycarbonate which is mechanically assembled facing optical fibres ( 13 ).
[0063] In a third embodiment, protective layer ( 17 ) can also be attached so that it is intimately bonded to optical fibres ( 13 ) by means of a spray coating process, especially a process for applying a resin which is commonly referred to as a “gel coat”.
[0064] What is more, fire-resistance comparison studies have been conducted using special-purpose measuring tools in accordance with the applicable standards concerning flexible and rigid materials, NF F 92 503 and NF 92 501, railway applications NF 16 101, technical specification SNCF/RATP STM-S-001 and building P 92 502, respectively.
[0065] A complex was produced, by way of example, using a rigid metallic backing, an MSP (Modified Silicone Polymer)-based bonding intermediate, optical fibres with a PC core and ground threads made of a flame-resistant polyester such as Trevira® CS in particular.
[0066] The textile web thus formed may comprise, in the weft direction, an alternation of 17 optical fibres and 17 ground threads per centimetre made of “non-fire” polyester such as threads marketed under the Trevira® CS brand name and, in the warp direction, 50 ground threads per centimetre made of Trevira® CS brand polyester for example. The size of the ground threads is 167 dtex.
[0067] This complex successfully withstood the applicable fire-resistance tests and achieved the highest fire-resistance and smoke behaviour classification for materials intended for use in railway and building construction applications.
[0068] In fact, the complex has a class M1 fire-behaviour rating in accordance with Standards NF P 92 501 and P 92 502.
[0069] The complex has a class F1 smoke-behaviour rating in accordance with Standards NF X 10-702 (1,2,3,4,5) and NF X 70-100.
[0070] The above description makes it apparent that the illuminating complex in accordance with the invention has many advantages, in particular:
[0071] It makes it possible to produce an illuminating surface which is rigid, light and thin;
[0072] It can be used as an actual partition or light ceiling without the need for any assembly operations;
[0073] It has extremely good mechanical strength properties;
[0074] It makes it possible to dissipate heat very quickly, can withstand fire and does not release any toxic smoke, depending on the nature of its constituent materials. | An illuminating complex includes a light source having a textile web incorporating optical fibres in the warp and/or weft directions. The fibres are associated with binding yarns, and the optical fibres are capable of emitting light laterally. The textile web is attached to a rigid or semi-rigid backing, and a bonding intermediate allows the textile web to be at least partly attached in an irreversible manner to a rigid backing. | 3 |
BACKGROUND OF THE PRESENT INVENTION
[0001] 1. Field of Invention
[0002] The present invention relates to a heating arrangement, and more particularly to a heater having a reflector for distributing radiant heat of the heater.
[0003] 2. Description of Related Arts
[0004] People prefer to take part in outdoor activities in our spare time, but they may need to bring a heater in a cold day. For example, they may employ a burner or a furnace to for keeping warm during an outdoor party in winter. A typical burner is a heating device for burning fuel so as to produce radiant heat, so that people can sit around the burner to receive radiant heat of the burner for keeping warm of our bodies.
[0005] But as the radiant heat of the burner is dispersed into the surrounding environment, people sitting around of the burner may not receive the same amount of energy. In other words, the people who are sitting near the burner will get relatively more radiant heat while the people being far from the burner will receive relative less radiant heat. As a result, the one sitting near the burner may feel hot, but another one sitting far away from the burner may still feel cold after staying around the burner for a relatively long period of time.
[0006] In addition, since the radiant heat of the burner is evenly distributed, the amount of heat may not be much enough for warming the people around the burner immediately, in other words, the radiant heat of the burner should be collected and concentrated so that they can be directed to a desired area.
[0007] Therefore, a more effective heater is required to make full use of the radiant heat and users can receive desirable amount of heat from the heater so as to get warm in a relatively short period of time.
SUMMARY OF THE PRESENT INVENTION
[0008] The main object of the present invention is to provide a heating arrangement comprising a heater and a reflector, wherein the reflector is coupled with the heater for concentrating and dispersing heat to a desired area.
[0009] Another object of the present invention is to provide a heating arrangement comprising a heater and a reflector, wherein the reflector comprises a curved reflecting board for reflecting the radiant heat produced by the heater to a certain direction, so that the radiant heat of the heater is concentrated.
[0010] Another object of the present invention is to provide a heating arrangement comprising a heater and a reflector, wherein the reflector is movably mounted on the heater so that the reflector is adapted to move between a positions near to or far from the heater so as to direct the radiant heat to the corresponding desired area which is near to or far from the heater.
[0011] Another object of the present invention is to provide a heating arrangement comprising a heater and a reflector, wherein the reflector is rotatably mounted on the heater so as to direct radiant heat to various directions by rotating the reflector, so that a desired area can be distributed with an amount of concentrated heat.
[0012] Another object of the present invention is to provide a heating arrangement comprising a heater and a reflector, wherein the heater is provided at a focal point of the reflector so that the radiant heat of the heater is focused by the reflecting board of the reflector, therefore, the maximum radiant heat can be collected for directing to a certain area and thus this area can be heated to a desired temperature in a relatively short period of time.
[0013] Another object of the present invention is to provide a heating arrangement comprising a heater and a reflector, wherein the heater is a burner for burning fuel, the reflector is coaxially provided around the burner, wherein the reflector is adapted to slide along the outer circumference of the burner so as to direct concentrated radiant heat to a desired area.
[0014] Additional advantages and features of the invention will become apparent from the description which follows, and may be realized by means of the instrumentalities and combinations particular point out in the appended claims.
[0015] According to the present invention, the foregoing and other objects and advantages are attained by a heating arrangement including a heater producing radiant heat and a reflector coupled with the heater, wherein the reflector comprises a reflecting board to reflect and concentrate the radiant heat.
[0016] Still further objects and advantages will become apparent from a consideration of the ensuing description and drawings.
[0017] These and other objectives, features, and advantages of the present invention will become apparent from the following detailed description, the accompanying drawings, and the appended claims.
BRIEF DESCRIPTION OF THE DRAWINGS
[0018] FIG. 1 is a perspective view of a heating arrangement according to a first preferred embodiment of the present invention.
[0019] FIG. 2 is an exploded view of the heating arrangement according to the above first preferred embodiment of the present invention.
[0020] FIG. 3 is a schematic view illustrating the reflector moving near to or far from the heater according to the above first preferred embodiment of the present invention.
[0021] FIG. 4 is a perspective view of a heating arrangement according to a second preferred embodiment of the present invention.
[0022] FIG. 5 is a schematic view illustrating the reflector rotating around the heater according to the above second preferred embodiment of the present invention.
[0023] FIG. 6 is a schematic view illustrating the heater being provided at a focal point of the reflecting board according to the above preferred embodiment of the present invention.
[0024] FIG. 7 is a schematic view illustrating the heater being provided away from the focal point of the reflecting board according to the above preferred embodiment of the present invention.
[0025] FIG. 8 is a perspective view of a heating arrangement according to a third preferred embodiment of the present invention, wherein the reflector slide along the outer circumference of the heater.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0026] Referring to FIG. 1 to FIG. 3 of the drawings, a heating arrangement according to a first embodiment of the present invention is illustrated, wherein the heating arrangement comprise a heater 10 and a reflector 20 . The heater 10 can be a conventional heating device like a burner or a burner which burns fuel to produce radiant heat, or an electric heater. As an example of this preferred embodiment, the heater 10 is a burner adapted for burning coal gas or other fuel source, the burner is convenient for taking out for outdoor cavities and also does not need electricity suppl.
[0027] Accordingly, the heater 10 comprises a heater body 11 having a burning cavity 12 , wherein coal gas or other fuel source is burnt in the burning cavity 12 for generating heat. The heater 10 further comprises a base 13 connected to the heater body 11 for supporting the heater body 11 and providing coal gas for a continual burning in the burning cavity 12 . In addition, a knob 14 is provided for adjusting the volume of the coal gas, in other words, the amount of the radiant heat of the heater 10 can be adjusted by operating the knob 14 .
[0028] Referring to FIG. 2 of the drawing, the reflector 20 is provided above the heater 10 in such a manner that the reflector 20 defines an inclining angle with respect to the heater 10 . The reflector 20 comprises a reflecting board 21 adapted to move near to or far from the heater 10 . The reflecting board 21 preferably has an inclining angle of 30°˜60° with respect to the heater 10 , and the reflecting board 21 is made of heat reflecting material so that the radiant energy of heat from the heater 10 is reflected on the reflecting board 21 . More specifically, the radiant heat which is projected to the reflecting board 21 will be reflected to the opposite direction, and thus the receiving area will be provided with almost double amount of radiant heat in comparison with the radiant heart received from a heater without a reflector. In other words, the reflector 20 is capable of collecting and concentrating radiant heat so that the desired area will be heated in a relatively short period of time.
[0029] In addition, the reflecting board 21 is capable of moving near to or far from the heater 10 , as shown in FIG. 3 , the heat receiving areas will be varied with respect to the movement of the reflecting board 21 so that the areas near to or far from the heater 10 will be distributed with concentrated amount of radiant heat, in other words, the areas far from the heater 10 also can be supplied with enough heat for keeping warm.
[0030] Accordingly, the reflecting board 21 has a round shape inner reflecting surface 211 , the reflector 20 further comprises a supporting frame 22 mounted to the reflecting board 21 . The supporting frame 22 has a central disk 221 provided at a center of the reflecting surface 211 of the reflecting board 21 , and a plurality of, for example three, retention arms 222 extended from the central disk 221 to an outer edge of the reflecting surface 211 to enhance the stability of the reflecting board 21 .
[0031] The reflecting board 21 can move forward or away from the heater 10 , the structure may be varied, according to this preferred embodiment, the reflector 20 comprises a connecting arm 23 extended from the heater body 11 of the heater, and an operating arm 24 movably mounted to the connecting arm 23 . More specifically, the connecting arm 23 is a hollow tube having a receiving channel 231 and the operating arm 24 is slidably provided in the receiving channel 231 , so that a height of the reflecting board 21 can be adjusted. Referring to FIG. 3 of the drawing, when the operating arm 24 moves up and down, the reflector 20 simultaneously moves up and down correspondingly, and thus the reflector 20 is adapted to move near to or far from the heater 10 so as to direct the radiant heat to a desired area.
[0032] Another advantage of this heating arrangement is that when the heater 10 is provided at a corner, the reflector 20 can collect and direct the waste heat to the opposite direction, and thus the efficiency of the heater 10 is improved.
[0033] Referring to FIG. 4 to FIG. 5 of the drawings, a heating arrangement according to a second preferred embodiment of the present invention is illustrated, wherein the heating arrangement comprises a heater 10 A and a reflector 20 A rotatably coupled with the heater 10 A.
[0034] Accordingly, the reflector 20 A is provided above the heater 10 A, preferably, the reflector 20 A defines an inclining angle with respect to the heater 10 A, wherein the reflector 20 A comprises a reflecting board 21 A adapted for rotating around the heater 10 A. The structure may be varied, according to this preferred embodiment, the reflector 20 A comprises a connecting arm 23 A extended from the heater body 11 A of the heater 10 A, and an operating arm 24 A rotatably mounted to the connecting arm 23 A, the reflecting board 21 A is connected with the operating arm 24 A so that when the operating arm 24 A rotates with respect to the connecting arm, the reflector 20 A correspondingly rotates above the heater 10 A, and thus the reflector 20 A is adapted to direct the radiant heat to desired areas around the heater 10 A. What's more, if a certain area is required for heating for a longer period of time, the user can simply rotate the reflector to fix the reflector 20 A at a position facing towards that certain direction.
[0035] More specifically, referring to FIG. 5 of the drawing, the operating arm 24 A is mounted to the connecting arm 23 A by rivets, screws or the like in such a manner that the operating arm 24 A is rotatably connected to the connecting arm 23 A. And thus when a force is applied to actuate the operating arm 24 A to rotate with respect to the connecting arm 23 A, the reflector 20 A correspondingly rotates above the heater 10 A, and thus the reflector 20 A is adapted to direct the radiant heat regularly to desired areas around the heater 10 A regularly. Therefore, every corner around the heater 10 A can be provided with enhanced radiant heat regularly.
[0036] Referring to FIG. 6 of the drawing, the heater 10 A is preferably provided at a focal point of the curved reflecting surface 211 A, and thus the radiant heat can be concentrated via the curved reflecting surface 211 A, in other words, the radiant heat is focused to form a single direction heat beam so that the maxim radiant heat can be collected to be directed to a desired area, and simply moves the reflector 20 A with respect to the heater 10 A, the concentrated radiant heat can be directed to a different area.
[0037] Referring to FIG. 7 of the drawing, a heating arrangement according to an alternative mode of the above second preferred embodiment of the present invention is illustrated. Accordingly, the heater 10 A is installed away from the focal point of the reflecting board 21 A of the reflector 20 A, and thus the radiant heat is dispersed after reflecting by the reflecting board 21 A.
[0038] Referring to FIG. 8 of the drawing, a heating arrangement according to a third preferred embodiment of the present invention is illustrated, wherein the heating arrangement comprises a heater 10 B and a reflector 20 B, the reflector 20 B comprises a reflecting board 21 B having a curved reflecting surface 211 B, the reflecting board 21 B is coaxially provided with the heater 10 B, the reflector 20 B comprises a connecting arm 23 B wound around the heater body 11 B of the heater 10 B, and an operating arm 24 B pivotally extended from the connecting arm 23 B. Accordingly, the connecting arm 23 B provides a guiding channel 231 B around an outer circumference of the heater 10 B, wherein the operating arm 24 B is adapted to rotate in the guiding channel 231 B. The reflecting board 21 B engages with the operating arm 24 B in such a manner that when the operating arm 24 B rotates with respect to the connecting arm 23 B, the reflector 20 B correspondingly rotates along the outer circumference of the heater 10 B, and thus the reflector 20 B is adapted to direct the radiant heat to desired areas around the heater 10 B.
[0039] One skilled in the art will understand that the embodiment of the present invention as shown in the drawings and described above is exemplary only and not intended to be limiting.
[0040] The embodiments have been shown and described for illustrating the functional and structural principles of the present invention. The person of ordinary skill in the art will appreciate that various changes may be made without departure from such spirit and scope of the invention. | A heating arrangement includes a heater producing radiant heat and a reflector coupled with the heater, wherein the reflector has a reflecting board to reflect and concentrate the radiant heat. | 5 |
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention relates to an ejection device, and more particularly to an ejection device that is manufactured independent from and implemented with a subscriber identity module (SIM) connector having a tray used to accommodate a SIM card to conveniently eject the SIM card.
[0003] 2. Description of Related Art
[0004] Subscriber identity card (SIM) connectors are used in numerous electronic devices such as cellular phones, and personal data assistants to accommodate and hold a SIM card that records a user's identification information. International standards have been designated for dimension and shape of the SIM cards so the connectors must correspond to these, but ejection devices for SIM card connectors may be designed at each manufacturer's desire. Therefore, manufacturers are free to develop various holding and ejection devices for SIM card connectors. However, some systems are very awkward to use and may damage the SIM card. A conventional connector comprises an insulative housing including an ejection device formed integrally with the insulative housing as a single piece. However, manufacturing ejection-integrated device is difficult so production of the ejection-integrated connector is slow and expensive, resulting in higher cost of the connector and prevents economies of scale from being efficiently applied. Also ejection-device-integrated connectors are inflexible and must be designed around, preventing easy application and retrofitting to current designs.
[0005] To overcome the shortcomings, the present invention provides an ejection device to mitigate or obviate the aforementioned problems.
SUMMARY OF THE INVENTION
[0006] The main objective of the invention is to provide an ejection device that is manufactured independently from and implemented with a subscriber identity module (SIM) connector having a tray used to mount a SIM card to conveniently eject the SIM card.
[0007] An ejection device in accordance with the present invention is manufactured independently from but implemented with a subscriber identity module (SIM) connector comprising an insulative housing and a tray having a SIM card mounted therein and has a bracket, a push button, a link and an ejection lever. The push button is mounted slidably on the bracket. The link is mounted slidably on the bracket and is connected with the push button. The ejection lever is mounted pivotally to the bracket, is connected to the link and selectively pushes the SIM card out of the tray. The ejection device may be pre-fabricated or formed with the connector so can be easily retrofitted to current designs or added simply to any SIM card connector and greatly facilitates SIM card removal whilst benefiting from reduced production costs from simplification and greater economies of scale.
[0008] Other objectives, advantages and novel features of the invention will become more apparent from the following detailed description when taken in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0009] FIG. 1 is a perspective view showing an ejection device in accordance with the present invention and a connector mounted on a printed circuit board;
[0010] FIG. 2 is a partially exploded, top perspective view of the connector with the ejection device in FIG. 1 ;
[0011] FIG. 3 is a partially exploded, bottom perspective view of the connector with the ejection device in FIG. 1 ;
[0012] FIG. 4 is an exploded perspective view of the connector along with the ejection device in FIG. 2 ;
[0013] FIG. 5 is an enlarged perspective view of the connector in FIG. 4 ;
[0014] FIG. 6 is an enlarged exploded perspective view of the connector in FIG. 4 ; and
[0015] FIG. 7 is an enlarged exploded perspective view of the ejection device in FIG. 4 .
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0016] With reference to FIGS. 1 to 3 , an ejection device ( 5 ) is used with a subscriber identify module (SIM) connector to hold a SIM card and has an insulative housing ( 2 ), a plurality of terminals ( 3 ) and a tray ( 4 ).
[0017] With further reference to FIG. 5 , the insulative housing ( 2 ) may be mounted on a printed circuit board (PCB) and has a bottom ( 21 ), two opposite sidewalls ( 22 ), a plurality of mounting holes ( 211 ), a plurality of openings ( 212 ), a positioning protrusion ( 213 ), a pair of strips ( 23 ) and a plurality of mounting posts ( 24 ).
[0018] With further reference to FIGS. 4 and 6 , the bottom ( 21 ) of the insulative housing ( 2 ) has an inner surface and an outer surface.
[0019] The sidewalls ( 22 ) are formed on and protrude up from the inner surface of the bottom ( 21 ). Each sidewall ( 22 ) has a track slot ( 221 ) defined in the sidewall ( 22 ).
[0020] A space is defined in the insulative housing ( 2 ) between the sidewalls ( 22 ).
[0021] The mounting holes ( 211 ) are cross-shaped, are defined through the bottom ( 21 ). Each mounting hole ( 211 ) has a longitudinal section, a transverse section, a mounting slot ( 2111 ), a soldering recess ( 2112 ) and a pair of wing recesses ( 2114 ). The longitudinal section is located perpendicular to the sidewall ( 22 ) and has two ends. The transverse section perpendicularly intersects the longitudinal section and has two ends. The mounting slot ( 2111 ) is defined in the outer surface of the bottom ( 21 ) respectively at one end of the longitudinal section. The soldering recess ( 2112 ) is defined in the outer surface of the bottom ( 21 ) at the other end of the longitudinal section and has a pair of hook mounts ( 2113 ) formed on the inner surface. The wing recesses ( 2114 ) are defined in the outer surface of the bottom ( 21 ) respectively at the ends of the transverse section.
[0022] The openings ( 212 ) are defined through the bottom ( 21 ) and communicate with the mounting holes ( 211 ).
[0023] The positioning protrusion ( 213 ) is formed on and protrudes from the inner surface of the bottom ( 21 ).
[0024] The strips ( 23 ) are formed on and protrude respectively from the sidewalls ( 22 ) and are used to mount the SIM card connector on the PCB.
[0025] The mounting posts ( 24 ) are formed on and protrude from the outer surface of the bottom ( 21 ) and are mounted on the PCB.
[0026] The terminals ( 3 ) are electrically conductive, are made of metal, correspond to and are mounted respectively in the mounting holes ( 211 ) and electrically connect detachably to contact terminals on the SIM card to allow data and power to be transmitted between the SIM card and the PCB. Each terminal ( 3 ) has a mounting portion ( 31 ), a contacting portion ( 32 ), a soldering portion ( 33 ) and a pair of fastening portions ( 34 ).
[0027] The mounting portion ( 31 ) is mounted in the mounting slot ( 2111 ) in a corresponding mounting hole ( 211 ) in the bottom ( 21 ) and has a pair of fastening protrusions ( 311 ). The fastening protrusions ( 311 ) are formed on and protrude from the mounting portion ( 31 ) and are mounted in the mounting slot ( 211 ) to prevent movement of the terminals ( 3 ). The contacting portion ( 32 ) is resilient, is formed on and protrudes from the mounting portion ( 31 ), is mounted in and protrudes out from the mounting holes ( 211 ) in the bottom ( 21 ) of the insulative housing ( 2 ) and has a hook ( 321 ). The hook ( 321 ) is formed on and protrudes from the contacting portion ( 32 ) and is mounted on the hook mount ( 2113 ).
[0028] The soldering portion ( 33 ) is formed on and protrudes from the mounting portion ( 31 ), is mounted in the soldering recess ( 2112 ) in the corresponding mounting hole ( 211 ) and is soldered onto the PCB to form a secure electrical connection.
[0029] The wings ( 34 ) are formed on and protrude from soldering portion ( 33 ) and are mounted respectively in the wing recesses ( 2114 ) in the corresponding mounting hole ( 211 ) to hold the terminals in place.
[0030] The tray ( 4 ) is mounted detachably in the insulative housing ( 2 ), may accommodate the SIM card and has a body ( 41 ) and a resilient tab ( 42 ).
[0031] The body ( 41 ) is detachably mounted slidably in the space of the insulative housing ( 2 ). The body ( 41 ) has a front edge, a rear edge, two opposite sides, a pair of lips ( 411 ), a cavity ( 412 ), a tab slot ( 413 ), a tab recess ( 414 ), a pair of retaining tabs ( 415 ), a positioning recess ( 416 ), a stopper ( 417 ) and a guide ( 418 ).
[0032] The lips ( 411 ) are formed respectively on, protrude respectively from the sides and are slidably mounted respectively in the track slots ( 221 ) in the sidewalls ( 22 ) of the insulative housing ( 2 ).
[0033] The cavity ( 412 ) is defined in the body ( 41 ), accommodates and holds the SIM card.
[0034] The tab slot ( 413 ) is defined through the body ( 41 ) and communicates with the cavity ( 412 ).
[0035] The tab recess ( 414 ) is defined in the body ( 41 ) and communicates with the tab slot ( 413 ).
[0036] The retaining tabs ( 415 ) are formed on and protrude from the body ( 41 ), correspond to the tab slot ( 413 ) and securely retain the SIM card in the cavity ( 412 ).
[0037] The positioning recess ( 416 ) is defined in the body ( 41 ) and engages selectively with the positioning protrusion ( 213 ) on the bottom ( 21 ) of the insulative housing ( 2 ) to hold the tray ( 4 ) securely in the insulative housing ( 2 ).
[0038] The stopper ( 417 ) is formed on the front edge and selectively abuts against the insulative housing ( 2 ) to prevent the tray ( 4 ) from sliding too far into the insulative housing ( 2 ).
[0039] The guide ( 418 ) is formed on the rear edge and is tapered to form two inclined surfaces. The inclined surfaces smoothly guide the contacting portions ( 32 ) of the terminals ( 3 ) on the insulative housing ( 2 ) into the cavity ( 412 ) to contact the terminals of the SIM card in the cavity ( 412 ).
[0040] The resilient tab ( 42 ) is mounted in the tab slot ( 413 ), tightly presses the SIM card to prevent the SIM card from moving and has a proximal end mounted securely in the tab recess ( 414 ).
[0041] With further reference to FIG. 7 , the ejection device ( 5 ) is manufactured separately from and mounted adjacent to the connector ( 100 ) and may be pre-fabricated before mounting. The ejection device comprises a bracket ( 51 ), a push button ( 52 ), a link ( 54 ) and an ejection lever ( 55 ) and may further have a biasing member ( 53 ).
[0042] The bracket ( 51 ) may be L-shaped, may be mounted on the PCB and is located adjacent to one sidewall ( 22 ) of the insulative housing ( 2 ). The bracket ( 51 ) has a top surface, a bottom surface, a side surface, an activating end, a pivoting end, a mounting block ( 512 ) and a slit ( 511 ) and may further have a keyed guide ( 513 ), a pivot hole ( 5112 ), a pivot pin ( 514 ), a plurality of retaining passages ( 515 ), a plurality of soldering members ( 57 ) and a plurality of mounting posts ( 56 ).
[0043] The side surface is defined between the top and bottom surfaces. The pivoting end is opposite to the activating end. The mounting block ( 512 ) is formed on and protrudes transversely from the side surface of the bracket ( 51 ) and may have a mounting bore. The mounting bore is defined longitudinally through the mounting block ( 512 ). The slit ( 511 ) is defined transversely through the pivoting end to define a flat void separating the top and bottom surfaces and at the pivoting end, and may be defined partially in the mounting block ( 512 ). The keyed guide ( 513 ) is defined longitudinally in the activating end in the side surface and may be a trapezoid cross section. The pivot hole ( 5112 ) is defined through the pivoting end of the bracket ( 51 ) and may communicate with the slit ( 511 ). The pivot pin ( 514 ) is mounted in the pivot hole ( 5112 ). The retaining passages ( 515 ) are defined in the bottom surface of the bracket ( 51 ). The soldering members ( 57 ) are securely mounted respectively in the retaining passages ( 515 ) and are soldered onto the PCB to secure the bracket ( 51 ) on the PCB. The mounting posts ( 56 ) are formed on and protrude from the bottom surface and are mounted in the PCB.
[0044] The push button ( 52 ) is mounted slidably on the bracket ( 51 ), selectively abuts the mounting block ( 512 ) and may have a slide. The slide is formed on and protrudes from the push button ( 52 ), corresponds to and is mounted slidably in the keyed guide ( 513 ), may have a trapezoid cross section corresponding to that of the guide rail ( 513 ) to allow the push button ( 52 ) to be held securely in and slide easily in the bracket ( 51 ).
[0045] The link ( 54 ) is mounted slidably in the bracket ( 5 ), may be through the mounting block ( 512 ), is connected with the push button ( 52 ) and has a main portion ( 54 a ), an elongated portion ( 54 b ) and a notch ( 542 ). The main portion ( 54 a ) may be mounted slidably in the slit ( 511 ) in the mounting block ( 512 ) and selectively abuts the mounting block ( 512 ). The elongated portion ( 54 b ) is formed on and protrudes from the main portion ( 54 a ), is mounted slidably through the mounting block ( 512 ) and may be mounted slidably through the mounting bore of the mounting block ( 512 ). The elongated portion ( 54 b ) has a proximal end connected with the main portion ( 54 a ) and a distal end mounted securely in the push button ( 52 ). The notch ( 542 ) may be semicircular and is defined in the main portion ( 54 a ).
[0046] The ejection lever ( 55 ) is mounted pivotally on the bracket ( 51 ), is connected pivotally with the link ( 54 ), may be in the slit ( 511 ) in the bracket ( 51 ) and has a body segment ( 551 ), a connecting segment ( 552 ) and an ejecting segment ( 553 ). The body segment ( 551 ) is mounted rotatably in the slit ( 511 ) and may further have a pivot bore ( 5511 ). The pivot bore ( 5511 ) is defined through the body segment ( 551 ) and is mounted rotatably around the pivot pin ( 514 ) in the pivot hole ( 5112 ) of the bracket ( 51 ). The connecting segment ( 552 ) is forked, is formed on and protrudes from the body segment ( 551 ), is connected with the link ( 54 ) and has a connecting prong and a retaining prong ( 552 c ). The connecting prong stepped, is formed on and protrudes from the connecting segment ( 552 ) and has an upright section ( 552 a ) and a retaining section ( 552 b ). The upright section ( 552 a ) is formed on and protrudes perpendicularly from the connecting segment ( 552 ) and is mounted rotatably in the notch ( 542 ) in the link ( 54 ). Therefore, when the ejection lever ( 55 ) pivots, the link ( 54 ) slides. The retaining section ( 552 b ) is formed on and protrudes perpendicularly from the upright section ( 552 a ). The retaining prong ( 552 c ) is formed on and protrudes from the connecting segment ( 552 ) at an interval from the retaining section ( 552 b ) to define a retaining slot located between the retaining section ( 522 b ) and the retaining prong ( 552 c ). The retaining slot holds the main portion ( 54 a ) of the link ( 54 ) to prevent the upright section ( 552 a ) of the ejection lever ( 55 ) from detaching from the notch ( 542 ) of the link ( 54 ). The ejection segment ( 553 ) may be L-shaped, is formed on and protrudes from the body segment ( 551 ) and selectively pushes and ejects the tray ( 4 ) with the SIM card out of the space of the insulative housing ( 2 ).
[0047] The biasing member ( 53 ) is a resilient element winding around the elongated portion ( 54 b ) of the link ( 54 ) between the push button ( 52 ) and the mounting block ( 512 ) of the bracket ( 51 ) to force the push button ( 52 ) and the mounting block ( 512 ) apart when no external force is applied to the push button ( 52 ). In this embodiment, the biasing member ( 53 ) is substantially a spiral spring.
[0048] To eject the tray ( 4 ) with the SIM card out of the insulative housing ( 2 ), a user pushes the push button ( 52 ). The link ( 54 ) is moved by the push button ( 52 ) and drives the connecting segment ( 552 ) to pivot around the pivot pin ( 514 ), thereby forcing the ejecting portion ( 553 ) to rotate and eject the SIM card out of the insulative housing ( 2 ).
[0049] The ejection device ( 5 ) is separate from the connector ( 100 ) and is pre-fabricated before cooperating in conjunction with the connector ( 100 ) instead of formed integrally to the connector ( 100 ). Therefore, the ejection device ( 5 ) may be added to conventional connectors with minimal or no redesign or integrated with conventional connectors simply after a design period, thereby improving products ending their development phase or even retrofitted to current models and may therefore take advantage of economies of scale to reduce costs whilst improving SIM card ejection.
[0050] 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. Changes may be made in the details, 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. | An ejection device is manufactured independently from but implemented with a subscriber identification module (SIM) connector comprising an insulative housing and a tray having a SIM card mounted therein and has a bracket, a push button, a link and an ejection lever. The push button is mounted slidably on the bracket. The link is mounted slidably on the bracket and is connected with the push button. The ejection lever is mounted pivotally to the bracket, is connected with the link and selectively pushes the SIM card out of the tray. The ejection device may be pre-fabricated or formed with the connector so can be easily retrofitted to current designs or added simply to any SIM card connector and greatly facilitates SIM card removal whilst benefiting from reduced production costs from simplification and greater economies of scale. | 7 |
SUMMARY OF THE INVENTION
The current invention relates to apparatus for prolonging the life of turbomachinery which is designed to operate at a substantially constant speed. The turbomachinery includes a drive turbine and operates in conjunction with a pressure swing adsorber bed pair, the bed pair having common clean air outlets and common purge air inlets and a plurality of valves coupled to the outlets and inlets which are actuated between open and closed positions. A first conduit means is provided for coupling the common clean air outlets to the turbomachinery drive turbine. A second conduit means is provided for coupling the turbomachinery drive turbine to the common purge air inlet. Means is provided for bleeding air pressure from the first and second conduit means in timed relation with actuation of the plurality or valves, so that pressure surge in the first and second conduit means due to valve actuation is avoided.
In another aspect of the invention an improvement is provided in a regenerable collective protection system for receiving contaminated air and providing clean air. The system has a pressure swing adsorber bed pair with common plenum purge air inlets and common plenum clean air outlets. A plurality of valves is contained in the bed pair which are actuated between closed and opened positions for controlling the purge air inlets and clean air outlets. The system has an air cycle machine with a turbine drive coupled to the clean air outlets through a clean air path for driving a compressor for system contaminated input air. A portion of the clean air from the pressure swing adsorber bed pair is conducted along a branch of the clean air path to the purge air inlets to purge the beds in accordance with the positioning of the plurality of valves. Improvement is provided in the form of means positioned in the clean air path for maintaining a substantially constant pressure in the path, so that the turbine drive is maintained at a substantially constant speed.
The invention also relates to a method of maintaining constant speed for a drive turbine in turbomachinery operating in conjunction with a pressure swing adsorber having a clean air outlet plenum and a purge air input plenum. The clean air output is used to drive the turbine and the turbine is connected to the purge air input plenum. The purge air input is controlled by actuation of a plurality of valves. The method comprises the step of bleeding off overpressure in the clean air output which is due to actuation of the plurality of valves, whereby substantially constant pressure is delivered to the drive turbine.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic depiction of a regenerable collective protection system utilizing the present invention.
FIG. 2 is a graph showing valve actuation sequence.
FIG. 3 is a graph showing pressure surge avoidance provided by the present invention.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Turning to FIG. 1 the invention herein will be disclosed in conjunction with a regenerable collective protection system (RCPS) wherein contaminated air is provided to the RCPS by a compressor stage 11. The compressor could be any source, for example, a compressor stage in a turbine engine. The contaminated air is conducted along a conduit 12 to a heat exchanger or precooler 13 which is contained within an air cycle machine 14, shown enclosed by dashed lines. The air cycle machine has a drive turbine 16 which drives a compressor 17 through a shaft 18. Mounted on the shaft and driven thereby is a fan 19 which provides air flow over a set of coils 21 in the heat exchanger 13 to remove heat from the contaminated air flowing through the conduit 12. The fan 19 is placed between the drive turbine 16 and the compressor 17 so that any contaminated air which may escape from the conduit 12 through the air bearings between the shaft 18 and the casing of the air cycle machine will be exhausted to ambient through the heat exchanger air flow to ambient caused by the fan 19. Such a heat exchanger or as precooler 13 is available as vendor identification No. 13430-1 from Alpha United, El Segundo, Calif. It is essential to preservation of the life of the air cycle machine 14 that the speed or the turbine 16 and therefore of the compressor 17 be constant. It is also essential, therefore, that the air flow driving the turbine 16 be free of overpressure pulses or pressure spikes. An appropriate air cycle machine is a modified T-46 air cycle machine manufactured by Air Research Manufacturing Company, Torrance, Calif.
The contaminated air is routed from the precooler 13 through the conduit 12 to compressor 17 and from compressor 17 is seen to be directed along a conduit 20 to an after cooler 22. The after cooler has heat exchange coils or mechanism 23 over which air is caused to flow by an electrically driven fan 24. The RCPS has an electronic controller 26 which adjusts the speed of the fan 24 in response to temperature which is sensed at the output side of a reheater 27 through which the contaminated air in conduit 20 flows. As a result, the contaminated air in conduit 20 is provided to the input of a pressure swing adsorber (PSA) bed air assembly 28 shown enclosed in dashed lines in FIG. 1. The after cooler 22 is available as vendor identification No. 13440-1 from Alpha United, El Segundo, Calif.
The contaminated air in conduit 20 is first delivered to a prefilter 29 which is also a water separator. An appropriate prefilter is seen in vendor's item identification No. A288825 obtained from Pall Safety Atmospheres, Pinellas Park, Fla. The output from the prefilter 29 is seen to be directed to a first inlet valve 31 and a second inlet valve 32 in the PSA bed pair. If the first inlet valve 31 is opened, contaminated air is directed into a first PSA bed 33 where the contaminants are removed, the air flows through a check valve 34 and into a contaminant free air conduit 36. While the first PSA bed 33 is cleansing contaminated air, a second PSA bed 37 is being purged by air flow from a clean air conduit 38 through a check valve 39 into the second bed 37. A second purge exhaust valve 41 is opened during this period to allow the cleansing air for the regeneration of the second PSA bed 37 to be thrown overboard through a purge outlet 42.
After a period of time wherein tilt: first PSA bed 33 has cleansed products carried in the contaminated air the first inlet valve 31 is closed and the second inlet valve 32 is opened. The second purge exhaust valve 41 is closed in sequence to be hereinafter described, and a first purge exhaust valve 43 is opened. As a consequence, contaminated air flows through the second inlet valve 32 into the second PSA bed 37 and through a second outlet check valve 44 into the contaminate free air conduit 36. At the same time clean air from conduit 38 is directed through a purge check valve 46 into PSA bed 33 to provide cleansing of the bed and is then exhausted through the open purge exhaust valve 43 and the purge air outlet 42 to ambient. A repressurization valve 47 is included in the pressure swing adsorber 28. A description of the function of valve 47, together with the other valves in the pressure swing adsorber 28 will be undertaken hereinafter. The pressure swing adsorber bed pair is known as vendor's item identification No. A288823, obtainable from Pall Safety Atmospheres, Pinellas Park, Fla.
From FIG. 1 it may be seen that the flow of air in clean air conduit 36 is used to drive the turbine 16 in the air cycle machine 14. Clean air is taken from the drive turbine 16 in a conduit 48 and a portion of it is split off into a conduit 49 to pass through the reheater 27 where the clean air is warmed by the hotter contaminated air passing therethrough in heat exchange coils 25. The warmed clean air in conduit 49 is delivered in part to the conduit 38 which provides the clean purge air through the purge check valves 46 or 39 as described hereinbefore. Another portion of the warmed clean air from conduit 49 is directed along the conduit 51 through a flow control valve 52. The flow control valve 52 is an electronically driven butterfly valve which provides an appropriate portion of warm air from conduit 49 to a mixer 53. The cooler contaminant free air in conduit 48 is also delivered to a similar flow control valve 54 which in turn proportions cooler contaminant free air to the mixer 53. Temperature sensors provide signals which are used by the system controller 26 to adjust the aperture within and therefore the flow through the flow control valves 52 and 54 to obtain an appropriate mix of hotter and cooler contaminant free air at the outlet side of the mixer 53 through a conduit 56 to a crew compartment. Flow control valves 52 and 54 are available as vendor identification No. 79318-326375 from Whittaker Controls, Inc., North Hollywood, Calif.
Turning now to FIG. 2 of the drawings, the sequence of operation of the valves in PSA bed pair 28 and the corresponding operation of the surplus air bypass valve, seen as item 57 in FIG. 1, will be described. In the first half cycle, FIG. 2 shows first inlet valve 31 open. Second inlet valve 32 is shown closed. The first purge exhaust valve 43 is also shown closed. The second purge exhaust valve 41 is opened so that bed 37 may be purged through purge outlet 42. During the first half of the cycle the second purge exhaust valve is open for the majority of the cycle and then is closed before the termination of the first half cycle. When the purge exhaust valve 41 is closed the repressurization valve 47 is opened between beds 33 and 37 so that pressure from the cleansing bed 33 is provided to bed 37 to bring the pressure therein up from ambient pressure during purging. The closure of the purge exhaust valve 41 causes the pressure surge or spike in the clean air conduit 38 which provides purge air to the PSA beds. The pressure spike may be seen to be experienced by the turbine 16 through the conduits 49 and 48 which would, if left unattenuated, alter the speed of the drive turbine 16. To combat this turbine speed altering pressure pulse, the surplus air bypass valve 57 is controlled by the system controller 26 to open about 100 to 150 milliseconds after purge exhaust valve 41 closes and repressurization valve 47 opens. The plurality of actuated valves 31, 32, 41, 43 and 47 in the PSA bed 28 have response times in the order of 300 milliseconds. The response time for the solenoid pressure relief valve used as surplus air bypass valve 57 is about 30 milliseconds. The system of FIG. 1 is therefore tailored to the response characteristics of the valves contained in the PSA bed 28. In this instance, the 100 to 150 millisecond delay for opening of valve 57 together with leaving valve 57 open for approximately 600 milliseconds, was found to optimize tile attenuation of the pressure surges or spikes in the system. An appropriate valve for use as surplus air bypass valve 57 is found in vendor's item identification No. 16F 24C6164A3FGC80 available from Parker Hannifin Corporation, Madison, Mass. as a solenoid pressure relief valve.
In the second half of the cycle as seen in FIG. 2 the first inlet valve 31 is closed and the second inlet valve 32 is opened. The first purge exhaust valve 43 is opened and the second purge exhaust valve 41 is closed. As a result contaminated air is cleaned by passing through the second bed 37 and the first bed 33 is purged of contaminated air products as hereinbefore described. Prior to the end of the full cycle the first purge exhaust valve 43 is closed and the repressurization valve 47 is opened to effect the result described hereinbefore 100 to 150 milliseconds after the opening of the repressurization valve 47 the surplus air bypass valve 57 is opened and held open for approximately 600 milliseconds. The pressure pulse or spike caused by valve actuation in the PSA bed pair 28 is therefore attenuated by bleeding pressure through bypass valve 57.
FIG. 3 is a depiction of the pressure pulses or spikes in the system without the surplus air bypass valve 57 as seen in the solid line of curve 58. The dashed line of curve 59 of FIG. 3 shows pressure fluctuation when the system utilizes the surplus air bypass valve 57 as described herein. The pressure diagram of FIG. 3 is aligned in timed sequence with the valve actuation diagram of FIG. 2 to better depict the occurrence of the pressure surges as a function of valve actuation.
Although the best mode contemplated for carrying out the present invention has been herein shown and described, it will be apparent that modification and variation may be made without departing from what is regarded to be the subject matter of the invention. | In a regenerable collective protection system the turbine of an air cycle machine is driven by a potion of the clean air output of a pressure swing adsorber bed pair in the system. The beds in the pair are used alternately to cleanse contaminated air. They are then alternately purged of contaminant products. Valves are used to direct these alternate operations. The valve closures cause overpressures in the clean air output. The overpressures are predictable in relation to the valve actuation sequence and are removed by coordinating operation of a surge air bleed valve in the clean air output with valve actuation in the pressure swing adsorber bed pair. | 1 |
FIELD OF THE INVENTION
This invention relates to data distribution in a textile dyeing apparatus, and, more particularly, to a system assigning individual, discrete time periods to a multiple number of dye applicators in an array. The system may be used to control the selective application of dyes or other marking materials to a moving substrate.
In one embodiment, the textile dying apparatus comprises multiple arrays or gun bars of individually addressable dye jets, which gun bars are positioned across and along the path of the moving substrate. Each of the individually addressable dye jets may be assigned a distinct time period in which to dispense dye such that a pattern to be marked on the substrate can have an increased complexity. This allows the production of textile products having dramatically improved detail as well as subtlety of color or shade.
BACKGROUND OF THE INVENTION
The pattern-wise application of dye stuffs to textile materials involves a large quantity of digitally encoded pattern data which must be sorted and routed to a large number of individual dye jets. Typically, these systems include several arrays or gun bars comprised of individually controllable or addressable dye jets which are arranged and spaced in a parallel relation generally above and across the path of a moving web of substrate. For a given desired pattern, each gun bar is associated with a single color of dye. Each of the jets in the gun bar directs a stream of dye at the moving substrate to apply the correct pattern to the substrate. When the jet is "firing" dye is being applied to the substrate and when the jet is "not firing" no dye is dispensed.
Precise pattern resolution along the direction of the substrate travel depends primarily upon the speed and precision with which the individual dye streams can be made to strike or not strike the continuously moving substrate. A problem with the prior known dyeing devices is that the devices are limited in that the period of time during which any of the dye streams in a given gun bar are allowed to strike the substrate must be the same for all jets in the gun bar. In effect, these prior devices are incapable of allowing one jet to dispense dye onto the substrate for a different period of time than another jet in the same gun bar. This limitation is reflected in an inability to produce side-to-side shade variations simply by varying the quantity of dye applied to the substrate across the width of the given gun bar.
There is therefore needed a simple and efficient process and apparatus for individually assigning firing times to each dye jet across a gun bar.
SUMMARY OF THE INVENTION
By use of the novel programming described herein, as applied to the textile dying machines generally described above, textile products having dramatically improved detail as well as subtlety of color or shade may be produced. As discussed above, this invention is believed to be applicable to a variety of marking or patterning systems wherein large quantities of pattern data must be allocated and delivered to a large number of individually controllable imaging locations, and is not limited to use in connection with the patterning devices disclosed herein.
The present invention makes use of a programmable computer for assigning individual firing times to each dye jet across a gun bar. The method includes an initial value determination phase, a gun bar data generation phase and a gun bar data output phase.
During the initial value determination phase, based on the user's selection of the pattern to be applied to the substrate, an array of firing times is prepared as requested by the user corresponding to the pattern areas used in the selected pattern. This phase also determines the values of several variables that are used to control the operation of the subsequent phases. The gun bar data generation phase prepares an array of individual firing instructions for each jet in each gun bar. The individual firing instructions are then distributed during the gun bar data output phase to the physical apparatus.
It is an advantage of the present invention to provide an efficient software system whereby the individual firing times can be assigned to a plurality of jets in a gun bar.
The above discussion is a summary of certain deficiencies in the prior art and advantages of the invention described herein. Other advantages will be apparent to those skilled in the art from the detailed discussion of the invention that follows.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a diagrammatic side elevation view of a metered jet dyeing apparatus to which the present invention is particularly well adapted;
FIG. 1A is a perspective view of a gun bar which may be used in the apparatus of FIG. 1;
FIG. 2 is a flow chart describing the operation of the present invention;
FIG. 3 is a flow chart describing the operation of the present invention;
FIG. 4 is a flow chart describing the operation of the present invention;
FIG. 5 is a schematic block diagram of the present invention;
FIGS. 6A-6F illustrate a simple example of the operation of the present invention;
FIGS. 7A and 7B further illustrate the example of FIGS. 6A-6F;
FIG. 8 is a diagram illustrating the time sequence of operations performed in the example.
DETAILED DESCRIPTION
For purposes of discussion, the present invention will be described in conjunction with the metered jet patterning apparatus shown in FIG. 1. The patterning machine includes a set of eight individual gun bars 110 (gun bar 1 - gun bar 8) positioned within frame 21. Each gun bar 110 is comprised of a plurality of dye jets 111, perhaps several hundred in number, arranged in spaced alignment across the width of the gun bar, which gun bar extends across the width of the substrate 11. Substrate 11, for example, a textile fabric, is supplied from roll 9 and is transported through frame 21 and thereby under each gun bar 110 by conveyer 15 driven by a motor indicated generally at 17. After being transported under gun bars 110, substrate 11 may be passed through other dyeing related process steps such as drawing, fixing, etc.
An enlarged perspective view of one of the gun bars 110 and its associated operating hardware is shown in FIG. 1A. The gun bar 110 includes a plurality of dye jets 111 mounted in alignment, with an adjacent spacing appropriate to the degree of definition required by the pattern. Each dye jet 111 is comprised of a dye pipe 113 through which the dye may be pumped and a dispersing aperture 115 through which relatively high pressure air may be propelled. Further associated with each dye jet is an electronically controlled valve 117 which is interposed in the pressurized air lines 119 and 121 which serve to supply dispersing aperture 115 with pressurized air from manifold 123, which in turn is suitably connected, via regulator 125 and filter 127, to a source 129 of pressurized air. The operation of the valves 117 is controlled electronically by the programmable computer used by the method, illustrated schematically by controller 147. Associated with each dye pipe 113 is dye supply line 131 which extends from dye manifold 133, which in turn is fed, Via pressurizing pump 135 and filter 137 and associated conduits, from dye reservoir 139. Dye conduits 141 and 143 supply reservoir 139 with excess dye from manifold 133 and captured dye expelled by dye pipe 113 into containment trough 145, thus forming a recirculating dye system.
The apparatus described in FIGS. 1 and 1A is controlled by the programmable system of the present invention. Referring to the flow charts of FIG. 2 to FIG. 4, the operation of the present invention is divided conceptually into three parts or phases: initial value determination (FIG. 2); gun bar data generation (FIG. 3); and gun bar data output (FIG. 4). The flow charts describe the system for carrying out the method of the invention.
In the initial value determination phase (FIG. 2), based on the user's selection of the pattern to be applied to the substrate, an array of firing times is prepared as requested by the user corresponding to the pattern areas used in the selected pattern. The initial value determination phase also determines the values of several variables used to control the operation of the subsequent phases. In the gun bar data generation phase (FIG. 3), an array of individual firing instructions for each jet in each gun bar is prepared. In the gun bar data output phase (FIG. 4), the individual firing instructions for each jet in each gun bar are distributed. Each of these phases is discussed in greater detail below. It is understood that while the flow charts describe a textile dyeing apparatus using an array of gun bars to distribute the dye, the invention is applicable to any apparatus requiring different digital information to be supplied to a plurality of devices.
In order to more clearly understand the present invention, the following definitions, which are referred to throughout the description, are provided:
BARDATA(GB, LATCHROW#, JET) - A bit array of binary states indicating firing status of each jet for a given gun bar.
BAROFF(GB) - Gun bar offset=The total number of transducer pulses TXDCR between gun bar 1 and gun bar GB.
DIFFFT(N) - The difference (in time units) between FT(N) and FT(N-1), where FT(0)=0.
FIRING TIME, FT - Elapsed time during which a dye jet is "on" (i.e., dispensing dye).
FTCOUNT - Different firing time counter (from 1 to MAXFT).
GB - Gun bar identification number (GB=1, 2, . . . , MAXGB).
JET - Jet position counter across a given gun bar (JET=1, 2, . . . , MAXJET).
LATCHCOM - Command (sent to the gun bar latches) to latch BARDATA, thereby causing appropriate jets to fire for the time interval until the next LATCHCOM. LATCHROW#- Latch row counter (LATCHROW#=1, 2, . . . , TOTLATCH).
MAXBAROFF - Total number of transducer pulses TXDCR between gun bar 1 and gun bar MAXGB.
MAXFT - Total number of discrete firing times.
MAXGB - Maximum number of gun bars.
MAXJET - Total number of dye jets per gun bar.
PATTERN AREA #- Assigned identification number of a visually distinct region of the pattern which, in combination with all other such regions, comprises the overall pattern.
PATTERN LENGTH - Total number of pattern rows in the selected pattern (equal to the total number of transducer pulses TXDCR, disregarding gun bar offset BAROFF, needed to produce the selected pattern).
PATROW#- Pattern element row counter (based upon TXDCR count; PATROW#=1, 2, . . . , PATTERN LENGTH).
SOURCE PATTERN(M,N) - Array of PATTERN AREA#s (M=PATROW#, N=JET).
TOTLATCH - Total number of latch commands (LATCHCOM) sent to each gun bar to produce the selected pattern.
TXDCR - Transducer pulse, generated at each advance of a predetermined fixed length of substrate (e.g., the output of a rotary encoder in contact with a moving substrate).
The initial value determination phase, shown in FIG. 2, prepares an array of firing times corresponding to pattern areas used in the pattern and determines the value of several variables used to control the subsequent phases' operation. After beginning the method at 10, the next step 12 is for the user to select the pattern to be applied to the substrate. The pattern is chosen by name from among a number of available patterns. Corresponding to each pattern name is a two-dimensional source pattern array of pattern area identification codes PATTERN AREA #. The array is formed with one dimension corresponding to pattern row number PATROW # and the other to individual dye jet number JET, forming a two-dimensional matrix in which each cell in the matrix corresponds to a pattern element in the pattern to be applied to the substrate. The pattern area identification code in an individual cell of the matrix is an 8-bit unit uniquely identifying the pattern area to be associated with that pattern element.
Another two-dimensional data array, referred to as a look up table LUT, contains firing time data for the jets in each array. One dimension of this array corresponds to the pattern area number and the other to the gun bar number GB. Each cell in this array contains the firing time required for a jet in a particular gun bar to produce the specified pattern area. Method step 14 associates the source pattern array with the LUT to identify all of the discrete, non-zero firing times for any jet in any gun bar required to produce the selected pattern. These times are input by the user. Step 16 sorts the different firing times into ascending order and creates an arrayed string of firing times FT having a length MAXFT where MAXFT is the number of different firing times in the LUT. The first element in the string, FT(1), is the minimum firing time, while the last element, FT(MAXFT), is the maximum firing time for any jet in any gun bar.
The next steps 18 and 20 in the initial value determination phase calculate the values of two variables which control the operation of the subsequent phases. The first is the total number of latched commands TOTLATCH that must be issued to generate the pattern. A number of latched commands are issued to generate each pattern row in the pattern. The latch command is a command, sent to the latch (106 of FIG. 4) associated with each gun bar, to store the bar data BARDATA which causes the appropriate dye jets to fire for a time interval until the next LATCHCOM. The number of latched commands to be issued to generate one pattern row, LATCHCOM -- PER -- TXDCR, is one greater than the total number of firing times, MAXFT. The total number of latched commands that must be issued to generate the entire pattern depends on the number of pattern rows in the pattern and on the relative geometries of the gun bars. Firing instructions must be transmitted to the jets from the time the first pattern row passes by the first gun bar until the last pattern row passes by the last gun bar. The effective number of pattern rows that must be controlled is therefore the number of pattern rows in the pattern plus the number of pattern rows encompassed in the distance between the first gun bar and the last gun bar. The total number of latched commands required to generate the pattern is therefore the product of the number of latched commands per pattern row LATCHCOM -- PER -- TXDCR and the effective number of pattern rows, which is PATTERN LENGTH plus the maximum gun bar offset MAXBAROFF.
From the firing time string FT the method's next step 22 calculates a string of firing time differences DIFFFT having the same length as FT. The value of each element in the firing time difference string DIFFFT is the difference between the firing time in the corresponding element in FT and the preceding element in FT. For example, for the 3 element string FT where FT(1)=10 ms, FT(2)=25 ms, and FT(3)=30 ms, the values of DIFFFT would be DIFFFT(1)=10 ms, DIFFFT(2)=15 ms, and DIFFFT(3)=5 ms.
In the next step 24 of the initial value determination phase, the source pattern array may be transformed to full width if necessary. The width of the pattern to be applied to the substrate may be less than the full width of the substrate. Therefore, the source pattern table would need to be transformed to full width by either adding null value information or repeating the source pattern. For example, a 24 inch wide pattern applied to a 48 inch wide substrate would only fill half of the substrate, thus wasting substrate material. In such a case, the source pattern array would specify pattern areas for only one half of the dye jets. The method therefore could transform the source pattern array by doubling the width dimension of the array and copying the pattern information in the first half of the array into the newly-created second half. The resulting source pattern array would produce two patterns and utilize all of the jets across the gun bars. The initial value determination phase then terminates at step 26 when the method is ready to generate gun bar data.
Referring to FIG. 3, there is shown the gun bar data generation phase. In this phase, an array of individual firing instructions for each jet in each gun bar is prepared. The firing instruction array BARDATA is a three-dimensional array (GB, LATCHROW#, JET) with the first dimension corresponding to the gun bar number GB, the second dimension to latch command number LATCHROW#, and the third dimension to dye jet number JET. Each cell in the array contains a single bit, set to 1 if the individual jet in the particular gun bar is to be firing during the time period corresponding to the particular latch command. The array is filled with firing instructions in an iterative process. The following process is followed for each plane in the array, corresponding to a single gun bar.
The first step 30 in the array-filling process is to initialize the gun bar counter GB to 1, which means that the method first prepares firing instructions for gun bar 1. In the next step 32, the method initializes each cell in the current plane (GB, LATCHROW#, JET where GB=1, LATCHROW#=1 to TOTLATCH, and JET=1 to MAXJET) of the array to zero. The process then executes a three-tiered set of nested loops designated generally as 31, 33 and 35, respectively. The three looping counters are: 1) the pattern row number 58 PATROW# (ranging from 1 to the total number of pattern rows in the pattern); 2) the firing time counter 54 FTCOUNT (ranging from 1 to the number of firing times MAXFT in the firing time string FT); and 3) the jet number 50 JET (ranging from 1 to the number of jets in a gun bar). In steps 34, 36, and 38, these counters are initialized to 1. The following steps are then executed within the nested loops.
In the first step 40 within the nested loops 31, 33, 35, the pattern area identification code for the pattern element identified by the current pattern row (PATROW#) and the current jet (JET) is read from the transformed source pattern array. In the next step 42, the corresponding firing time for the current jet is read from the LUT based on the pattern area identification code just read and the current gun bar number. In step 44 the firing time is compared to the firing time in the element of the firing time string FT corresponding to the current value of the FTCOUNT looping counter 31. If the required firing time is greater than the current firing time value in string FT, then the method proceeds to steps 46 and 48, in which the bit in the appropriate row of the firing instruction array (BARDATA) is set to a 1. This signifies that the current jet in the current gun bar should be firing during the time period ending with the current firing time value in FT while the location on the substrate on which the current pattern row is to be applied is passing by the current gun bar.
The row of the firing instruction array in which the bit is set to 1 (i.e. the latch command number to which the firing instruction is assigned) is determined in step 46 and depends on the current pattern row number, the current gun bar number, the current gun bar offset, and the current firing time counter number, in the following relationship: ##EQU1## The bit in cell BARDATA(GB, LATCHROW#, JET) is then set to 1 in step 48 and the method proceeds to step 50.
If the required firing time is less than the current firing time value in string FT, then no change is made to the firing instruction array. This leaves the default bit value of zero at the position in the firing instruction array to which a 1 would have been written, signifying that the current jet in the current gun bar should not be firing during the time period ending with the current firing time value in FT while the location on the substrate on which the current pattern row is to be applied is passing by the current gun bar. The method then proceeds to step 50 and the firing instruction calculations are then repeated as each looping counter is incremented through its range and each loop 31, 33, 35 successively completed.
First, in step 50, the JET looping counter is incremented by one, and then, in step 52, the value of JET is tested to determine if firing instructions have been generated for all of the jets in the current gun bar for the current pattern row (i.e., if JET exceeds MAXJET). If not, the process inside the JET loop 31 (i.e., steps 40 to 50) is repeated until all of the jets have been treated. The method then proceeds to step 54, where the FTCOUNT looping counter is incremented and to step 56, where the value of FTCOUNT is tested to determine if firing instructions have been generated for all firing times for all jets in the current gun bar for the current pattern row (i.e., if FTCOUNT exceeds MAXFT). If not, the process inside the FTCOUNT loop 33 (i.e., steps 38 to 54) is repeated until all of the firing times for all of the jets have been addressed. The method then proceeds to step 58, where the PATROW# looping counter is incremented and to step 60, where the value of PATROW# is tested to determine if firing instructions have been generated for all firing times for all jets in the current gun bar for all pattern rows in the pattern (i.e, if PATROW# exceeds PATTERN LENGTH). If not, the process inside the PATROW# loop 35 (i.e., steps 36 to 56) is repeated until all of the firing times for all of the jets for all of the pattern rows in the pattern have been treated.
Finally, the process proceeds to step 62, where the looping counter GB is incremented and to step 64, where the value of GB is tested to determine if firing instructions have been generated for all firing times for all jets in all gun bars for all pattern rows in the pattern (i.e, if GB exceeds MAXGB). If not, the entire looping process described above (steps 32 to 60) is repeated for each gun bar, until firing instructions have been generated for all firing times for all jets for all pattern rows for all gun bars. The completed firing instruction array is then used in the gun bar data output phase of FIG. 4.
Referring to FIG. 4, there is shown the gun bar data output phase. In this phase, the individual firing instructions are distributed to each jet in each gun bar at the appropriate time to deposit the appropriate amount of dye in the appropriate location to form the desired pattern area in the desired location on the substrate. To accomplish this, the method controls the hardware elements shown schematically in the block diagram of FIG. 5. Each gun bar (GB 1 to GB N) is equipped with a latch 108 and a shift register 106 through which the firing instructions are routed to control the firing of the individual jets in the gun bar. The method is executed in a computer 100. Inputs to the computer 100 are received from a transducer source 104 and a timer 102. The transducer source 104, which can be, for example, a rotary encoder, is in contact with the substrate and sends transducer pulses TXDCR at each advance of a predetermined fixed length of the substrate, usually the length of a pattern row. The timer 102 is used as a source of firing time interrupts used for a purpose described below.
In the first step 70 of the gun bar data output phase shown in FIG. 4, two counters, LATCHROW#, which counts latch rows, and FTCOUNT, which counts firing times in the firing time string FT, are initialized to 1. In the next step 72 the shift register 106 for each gun bar is loaded with a single firing instruction for each of the jets in the gun bar from the firing instruction array BARDATA. The firing instructions are loaded from the plane of BARDATA corresponding to the first latch row number. The method then proceeds to step 74, where it awaits a transducer pulse TXDCR. When a transducer pulse is received from the transducer source 104, the method proceeds to step 76, where it generates a latch command LATCHCOM, which latches the data in the shift register 106, thus causing the appropriate jets to fire during the time interval until the next LATCHCOM is generated.
In the next step 78 of the method, the LATCHROW# counter is incremented and in step 80 LATCHROW# is tested to determine if the firing instructions in all of the latch command rows in the firing instruction array BARDATA have been executed (i.e., if LATCHROW# exceeds TOTLATCH). If so, no more dye is to be applied to the substrate, and the method proceeds to step 96, where it terminates operation. Otherwise, the method proceeds to step 82, where the firing time counter FTCOUNT is tested to determine if the longest firing time in the firing time string FT has elapsed (i.e., if FTCOUNT exceeds MAXFT). If so, the method proceeds to step 84, where the shift registers for each of the gun bars are loaded with firing instructions from the next row in BARDATA, corresponding to the latch command number after the one which had just been executed. FTCOUNT is then reset to 1 in step 86, and the method returns to step 74, where it awaits the next transducer pulse TXDCR, upon which the operation described above for steps 74 to 86 is repeated.
If the firing time counter FTCOUNT has not yet exceeded the number of firing times MAXFT (that is, if the longest firing time in the firing time array FT has not elapsed since the last transducer pulse), the method proceeds to step 88, where the timer is loaded with the next value in the firing time differences string DIFFFT. In the next step 90, the shift registers are loaded with data for the next firing command number. The method then increments the firing time counter FTCOUNT in step 92 and proceeds to step 94 where it awaits a firing time interrupt from the timer -02. When the interrupt is received, the method returns to step 76, where it generates a latch command LATCHCOM and repeats the subsequent steps described above.
The operation of the method described above can be better understood by use of the numerical example given below. The example shows the operation of the method in a rudimentary dye application system having two gun bars, each with two dye jets. The resolution of the system is assumed to be one inch, so that the size of a pattern element is one inch by one inch, and the substrate is two inches wide. Gun bar 1 applies yellow dye and gun bar 2 applies blue dye. The offset between the two gun bars is two inches, or two pattern rows. These relationships in the system are illustrated schematically in FIG. 6A.
The pattern to be generated by the method is identified as pattern A, shown in FIG. 6B. Pattern A incorporates three pattern areas: #1 (yellow), #2 (blue), and #3 (green). The source pattern array containing this information is shown in FIG. 6C. The LUT is shown in FIG. 6D. This array indicates that to form pattern area 1 (yellow) a jet in gun bar 1 must fire for 20 ms, while a jet in gun bar 2 does not fire at all. To form pattern area 2 (blue) a jet in gun bar 1 does not fire at all, while a jet in gun bar 2 fires for 20 ms. To form pattern area 3 (green) a jet in gun bar 1 must fire for 10 ms and a jet in gun bar 2 must also fire for 10 ms. The firing time string FT therefore contains two values: 10 ms and 20 ms, the only two firing times used in pattern A, as shown in FIG. 6E. The length MAXFT of string FT is 2. The firing time difference string DIFFFT contains two values, both 10 ms, as shown in FIG. 6F.
Three latched commands (one greater than the number of firing times MAXFT) must be issued for each pattern row, so the value of LATCHCOM -- PER -- TXDCR is 3. The effective number of pattern rows in the pattern is six (the pattern contains four pattern rows, and the offset between gun bars is two pattern rows). The total number of latched commands TOTLATCH that must be issued for the pattern is therefore 18 (3×6). Since it is assumed that the pattern occupies the full width of the substrate, it is not necessary to transform the pattern in this example.
The gun bar data generation phase is illustrated in FIGS. 7A and 7B. The three-dimensional firing instruction array BARDATA is shown schematically in FIG. 7A. The array has two planes (one for each gun bar) of 18 rows (one for each of the 18 latch commands) and 2 columns (1 for each jet). In the first step of the array-filling process, the 2-cell by 18-cell gun bar 1 plane is initialized with zeros in all of the cells. The iterative portion of the array-filling process then begins. In this example, the looping counters are looped to the following maximum values: PATROW#- 4; FTCOUNT - 2; JET - 2. The operations in the looping process on the plane in BARDATA corresponding to gun bar 1 are illustrated below. FIG. 7B shows the two planes of BARDATA separated and the firing instructions written to those planes in this phase. A 1 is indicated in a particular cell by shading the cell.
As the first execution step within the nested loops, the method reads the pattern area code from the source data array for pattern row number 1 and jet 1; this is pattern area code 1. In the next step, the firing time corresponding to pattern area code 1 is read from the LUT. The firing time is 20 ms. This firing time is then compared to the firing time in element FT(FTCOUNT) of the firing time string FT. FTCOUNT is still 1 at this point in the method's execution, so the firing time FT(1)=10 ms is compared to the required firing time of 20 ms. Since the required firing time is greater than FT(FTCOUNT), the appropriate bit in BARDATA must be set to 1 to indicate that the jet should be fired during the first firing time interval. The appropriate location for that bit is determined as follows.
Since the firing time counter FTCOUNT is 1, the bit should be put in the first latch command row of the appropriate set of latch command rows within BARDATA for the effective pattern row. The effective pattern row is determined by the current PATROW# value (in this case, 1) and the number of pattern rows by which the current gun bar is offset from the first gun bar (0 in this case because the first gun bar is being treated). In this case, the effective pattern row number is 1, so the bit is placed in the first latch command row in BARDATA. If, for example, the second gun bar was being treated in this step, the bit would be placed in latch command row 7, because the second gun bar is offset by 2 pattern rows (each comprising 3 latch command lines) from the first gun bar.
In the next execution step, the JET counter is incremented and the pattern area lookup, firing time lookup, and firing time comparison is conducted again. For the second jet, the pattern area code number is 3, for which the gun bar 1 firing time is 10 ms. Since this is equal to the FT(FTCOUNT) value of 10 ms, a 1 bit is again written to BARDATA, again in the first latch command row of the plane corresponding to gun bar 1. In the next outward loop of this phase of the method, the FTCOUNT looping counter is incremented. In this loop, the firing times required by each jet to produce the required pattern areas are compared to the firing time in FT(2), which is 20 ms, to determine if a 1 should be written to the appropriate cell in BARDATA. In this example, jet 1 would fire (firing time for pattern area 1 is 20 ms) while jet 2 would not (firing time for pattern area 3 is 10 ms). In the second latch command row of BARDATA for gun bar 1, a 1 would therefore be written for jet 1, but not for jet 2. Because MAXFT is 2, the FTCOUNT loop ends at this point, and PATROW# is next incremented and its loop repeated. In this loop, jet 1 is to produce a pattern area 3 and jet 2 is to produce pattern area 2. The respective firing times for jet 1 and jet 2 are thus 10 ms and 0 ms. Therefore, a 1 is written in latch command row 4 for jet 1, but not for jet 2. Nothing is written to latch command row 5 for these jets in this pattern row because neither jet fires longer than 10 ms. Note that latch command row 3 has not been addressed in the previous loop of PATROW#. The last latch command row for each pattern row is left with zeros in the cells to indicate that after the maximum firing time for any jet in each pattern row, no jets fire until the next pattern row. This is illustrated later in the example.
When all of the pattern rows have been treated and binary 1s written to the appropriate cells in the plane of BARDATA corresponding to gun bar 1, the process is repeated for gun bar 2. As an example, in the first pattern row, the firing times for jets 1 and 2 are 0 ms and 10 ms, respectively, corresponding to pattern areas 1 and 3. For the first pattern row the method therefore writes a 1 to the cell corresponding to jet 2, but not to jet 1, in latch command row 7 (reflecting, as noted above, that gun bar 2 is offset two pattern rows from gun bar 1). The method does not write a 1 in either of the cells in latch command row 8 because neither jet in gun bar 2 fires for longer than 10 ms to form the pattern areas in the first pattern row. The completed BARDATA array is shown in FIG. 7B.
After the gun bar data generation phase is completed, the method executes the gun bar data output phase. In this phase the data from BARDATA is loaded into the gun bar shift registers -06 and then latched to the dye jets in response to interrupts from the timer 102. The operation of this phase is illustrated in FIG. 8, where the contents of the shift registers for the first nine latch command lines are shown along with the sequence of firing time interrupts, the content of the timer, and the overall elapsed time.
The two shift registers 106 (one for gun bar 1 and one for gun bar 2) are initially loaded with the firing instructions from the first latch command row of BARDATA. When a transducer pulse TXDCR is received, the data is latched to the dye jets. (A LATCHCOM is generated, thus transferring the data from shift registers 106 to latch 108 thereby turning the appropriate jets on or off.) The interrupt timer 102 is loaded with the first value of the firing time difference string DIFFFT, which in this example is 10 ms. During the time the timer is delaying for the 10 ms, the method loads the next latch command row into the shift register from BARDATA, as shown in step 90. The method then waits for a firing time interrupt, as shown in step 94. After 10 ms have elapsed, the timer 102 sends a firing time interrupt, upon which the method latches the next, preloaded latch command row from BARDATA into latch 108 which latches the firing instructions to the dye jets. As shown in the example, both jets in gun bar 1 are instructed to fire on the first latch command row. However, after the first firing time interrupt, the second latch command row is latched, in which dye jet 2 is instructed to stop firing. It remains in a non-firing mode for two more pattern rows, when, in latch command row 7, it receives another instruction to fire. Assuming that the substrate is transported at the rate of one pattern row distance every 100 ms, the elapsed time between transducer pulses is 100 ms, and the total time from the initiation of the pattern can be tracked as shown in FIG. 8. | A control system for a textile dying apparatus processes and distributes digitally encoded pattern information. A substrate is moved on a path along which the surface of the substrate comes into operative range of a plurality of arrays arranged along the path of the substrate. Each of the arrays has a plurality of individual dye applicators capable of selectively projecting a stream of dye onto a predetermined portion of the substrate corresponding to a pattern element in a pattern composed of a pattern element matrix with a plurality of pattern elements in each of a plurality of pattern rows. Each pattern element is associated with a visually distinct pattern area. The dye applicators project dye for a time period determined by the pattern information. The method first determines a set of initial values. From the initial values it generates a firing command matrix having, for each dye applicator in each array, a firing command sequence corresponding to the pattern element to which that dye applicator may apply dye in each pattern rows. Finally, the method allocates, for simultaneous transmission to each dye applicator in each array, the firing command sequence in the firing command matrix corresponding to the pattern element in the pattern row to be applied to the predetermined portion of the substrate that is passing within operative range of the dye applicator at the time of transmission. | 3 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention concerns a self-supporting electrical overhead cable which includes cabled electrical conductors, tensile strength support elements, and optical waveguide elements made of metal coated tubes containing optical fibers.
2. Description of the Prior Art
Self-supporting electrical overhead cables including optical waveguides have been known for a long time. One known configuration example (which is described for example in the publication ETZ, Vol. 112 (1991) Book 10, page 482 and 483) is an overhead optical waveguide cable for overhead power lines. This known cable contains a special steel bundle core for overhead cables that is equipped with corrosion protection. Corrosion protection is necessary in the cable because the danger of contact corrosion exists with contact between special austenitic steel and the aluminum, Aldrey, Stalum or zinc-coated steel wires which make up the cable. The danger of corrosion is particularly high in the presence of a watery electrolyte containing chloride and oxygen, and/or f an electrical potential exists between the various cable elements.
As a defensive measure against corrosion, the known overhead cable provides the steel bundle core with an aluminum coating. The aluminum coating is formed by two aluminum bands or strips of 0.1 mm thickness each. The aluminum bands are cemented or otherwise adhesively attached lengthwise along the band edges of the aluminum bands. In this case, it is important to provide an equal electrical potential in the steel bundle core and in the armor wires that form the cable.
It has been found that these measures used in the above-described known cable do not provide secure protection against corrosion because the band edges of the aluminum bands cannot be tightly sealed. Additionally, the cemented aluminum bands can be damaged when they are stranded with the electrical conductors and the tensile strength metal elements which make up the cable. It has also been found that the wall thickness of the aluminum bands adds considerably to the outside diameter of the steel bundle core, and may cause a reduction in the number of optical waveguides contained within the cable.
SUMMARY OF THE INVENTION
Objects of the invention include the provision of a conductor cable or overhead cable having secure corrosion protection for tubes containing optical fibers, tensile strength elements and electrical conductors which constitute the conductor cable or the overhead cable.
Another object of the invention is to provide such a cable wherein optical fiber-containing tubes are diffusion-proof to thereby ensure the functional reliability of the optical fiber or fibers in the cable configuration.
It has been found that the foregoing objects can be readily attained by coating each optical fiber-containing tube within a cable with a thin-walled self-enclosed metal coating, which is in direct contact with the surface of the optical fiber-containing tube. By comparison with the prior art, such a metal coating in direct contact with the surface of the optical fiber-containing tube leads to a reduction in the outside diameter of the cable. Additionally, in the case of metal optical fiber-containing tubes, the self-enclosed metal coating provides secure protection against corrosion. Differences in the potential between the surface of the optical fiber-containing tube and the surrounding conductor strands or tensile strength elements are avoided.
In the event that the optical fibers are located inside plastic optical fiber-containing tubes, for example glass fiber reinforced plastic tubes, the thin, closed metal coating of the invention provides secure diffusion protection. Additionally, a tube according to the invention, which contains optical fibers, can be stranded without problems with the other elements of the cable configuration because the self-enclosed surface of the metal coating provides no points of attack for outside forces which exist during the manufacturing process.
It has been found that the metal coating of the invention, which is in direct contact with the surface of the optical fiber-containing tube being coated, limits the increase in cable diameter if, in accordance with a further development of the invention, the wall thickness of the metal coating is 5 to 70 μm, and preferably 15 to 40 μm.
If metal optical fiber-containing tubes are used, special advantages result from the fact that the metal coating can be metallurgically bonded to the surface of the metal tube. Such a bond is permanent, it provides a permanent corrosion protection to the inside of the stranded configuration of an overhead cable or a stranded conductor, and it also provides easier handling of the optical fiber-containing tube during the manufacturing process.
The self-enclosed, thin walled metal coating according to the invention can be applied to the surface of the optical fiber-containing tube in any desired manner. Thus, it has proven to be advantageous if the metal coating is a lengthwise welded thin walled metal band which is pulled down over the surface of the metal optical fiber-containing tube and is metallurgically bonded to it. Such a plating process ensures that the optical fiber-containing tubes, which are corrosion protected in this manner, can be wound on or off a spool without problems and be integrated into the stranded configuration of the overhead cable or phase cable.
If the respective applications require a particularly thin walled homogenous coating, a further development of the invention allows the metal coating to contain a sintered homogenous application of metal particles.
It has been found to be particularly advantageous if the metal coating is made of a homogenous material which is applied chemically or electrochemically. The metallurgical bond with the optical fiber-containing tube surface is ensured, the coating is homogeneously applied, and such a metal coating is diffusion-proof. A majority of overhead cables in the market today comprise a steel tube containing optical fibers in conjunction with aluminum-plated tensile strength steel wires and/or electrical conductors made of aluminum. In this case, the advantageous metal application is a layer of aluminum or an aluminum alloy, which is metallurgically bonded to the surface of the steel tube and is applied with a sintering process. Alternatively, the coating may be applied chemically or electrochemically, for example electrolytically.
The foregoing, and other objects, features and advantages of the present invention will become more apparent in light of the following detailed description of the exemplary embodiments thereof, as illustrated in the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a cross-sectional view of a cable in accordance with the present invention;
FIG. 2 is a cross-sectional view of a second embodiment of a cable in accordance with the present invention; and
FIG. 3 is a cross-sectional view of a third embodiment of a cable in accordance with the present invention.
DETAILED DESCRIPTION OF INVENTION
Referring to FIG. 1, a cross-sectional view of an overhead cable is illustrated which has, for example, an outside diameter of about 12 mm, and which contains an inner supporting core (core wire) 1 in the form of an aluminum-sheathed steel wire. Twisted around the core wire 1 is a first layer of aluminum-plated steel wires 2. A second layer of wires above the first layer of aluminum-plated steel wires 2 includes power conducting aluminum or aluminum-alloy wires 3.
The first layer of wires immediately above the core wire 1 comprises at least one metal tube 4, preferably made of special steel, and having a diameter which corresponds to the diameter of the adjacent aluminum-plated steel wires 2. The metal tube 4 is filled, for example with a thixotropic gel, in which optical fibers 9 are imbedded lengthwise. Preferably, the optical fibers 9 have a defined excess length with respect to the metal tube 4.
The metal tube 4 is coated with a self-enclosed, thin walled metal coating 5 of the invention, which in the present case is made of aluminum or an aluminum alloy, to prevent corrosion from appearing inside the stranded configuration. The metal coating 5 is preferably applied electrolytically in a thickness of 10 to 20 μm, tightly surrounds the metal tube 4 with a smooth homogeneous surface, and therefore offers no points of attack for the mechanical forces that are present during the manufacture of the overhead cable.
Referring now to FIG. 2, a self-supporting overhead cable is illustrated in which an armor layer of aluminum-plated steel wires 7 is twisted around a central steel tube 6. A second layer of conductor elements 8, preferably made of aluminum or a suitable aluminum alloy, surround the armor layer of aluminum-plated steel wires 7. Optical fibers 9 are arranged inside the steel tube 6. The optical fibers have at least a six per thousand excess length with respect to the length of the steel tube 6. The space 10 inside of the steel tube may be filled with a thixotropic gel, with a petroleum jelly basis for example.
In accordance with the invention, the steel tube 6 has a thin walled metal coating 11, of aluminum or an aluminum alloy in the present case because of the materials of the other elements of the stranded configuration example. The wall thickness of this metal coating 11 is for example 30 μm, it is produced for example by forming an aluminum band around the steel tube, which is then welded lengthwise and pulled over the tube in several operating stages. However, the metal coating 11 can also be produced by applying the aluminum material in the form of a powder, which is preferably applied under a protective gas to prevent oxidation. The applied layer is subsequently subjected to a sintering process.
Another method for forming the metal coating, as described with respect to FIG. 1, is an electrolytic application, done for example under a protective gas, to produce a diffusion-proof, homogenous aluminum coating 11 on the steel tube 6.
Another configuration of the invention is shown in FIG. 3. This configuration includes an inner core profile 12, for example in the form of a metal wire, made perhaps of steel or aluminum or steel in plated form. A first layer of aluminum-sheathed steel wires 13 (placed as armor wires), and steel tubes 14 (to receive the optical fibers) is placed over the inner core profile 12. As shown in FIG. 3, each of the steel tubes 14 is located between two armor wires 13-and each steel tube 14 has a smaller diameter than the adjacent armor wires 13. The armor wires 13 are fixed in their position by insertion into lengthwise grooves 15 formed in the inner core profile 12, so that the steel tubes 14 are protected when the cable is bent or subjected to other mechanical loads, for example in the form of vibrations during operation. A second layer which includes aluminum wires 16 (which serve to supply power) surrounds the first layer of armor wires 13 and steel tubes 14.
Optical fibers 17 are located inside the steel tubes 14. An excess length in the cable configuration is given by the selected twisting pitch of the various cable elements, and if necessary the optical fibers 17 are also provided with excess length in the steel tubes 14. The steel tubes may be made of special steel. The steel tubes 14 have a thin, closed homogenous metal coating 18, of 40 μm for instance. This metal coating 18 can be provided in accordance with the already mentioned manufacturing process examples described herein above with respect to FIGS. 1 and 2.
The invention is described herein as including steel tubes which are used for the optical fibers in the configuration, aluminum wires for the electrical conductors and aluminum-plated steel wires for the tensile strength elements. However, it may be desirable to deviate from these materials which are used as a rule today, and use other conductive metals in the cable configuration, for example copper or copper alloys. When such a copper or copper alloy is used, the protective metal coatings for the optical fiber-containing tubes must be made of a corresponding material, namely also of copper or a copper alloy, to avoid a difference in the electrical potential.
Additionally, it will be understood by those skilled in the art that the invention is of course not limited to the use of metal optical fiber-containing tubes. Plastic tubes, preferably reinforced with fiber glass, can be used to form the optical fiber-containing tubes if desired. Even if the protection of the cable configuration against corrosion is less important when plastic optical fiber-containing tubes are used, it may be necessary to make the plastic tubes diffusion-proof. This is achieved with the invention because the surface of the plastic tube is coated with a layer of a thin closed homogenous metal. Even if no metallurgical bond with the plastic tube material is possible in this case, in contrast to the known state of the art, the invention provides the secure protection against the introduction of moisture and other contamination into the optical fiber-containing tube.
Independently of the configurations described and illustrated herein, the present invention is applicable in all cases where metal tubes serve to receive optical fibers in such self-supporting overhead cables, where the appearance of corrosion can be expected because of differences in the electrical potential due to the materials being used for the metal tubes or for the other component elements.
Although the invention has been described and illustrated with respect to exemplary embodiments thereof, the foregoing and various other changes, omissions and additions may be made therein and thereto without departing from the spirit and scope of the present invention. | An electrical overhead cable includes: cabled electrical conductors (3); tensile strength support elements (1, 2); and optical waveguide elements made of metal coated tubes (4) containing optical fibers (9). The metal coating on the optical fiber-containing tubes is a thin, self-enclosed metal layer (5), which is in direct contact with the surface of the tube (4). | 7 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims the benefit of the following earlier-filed U.S. Provisional Application in accordance 35 USC 119: No. 60/888,721 entitled “Fuzzy Matching,” filed Feb. 7, 2007 in the names of Mayer and Narayanan. The entirety of the foregoing application is incorporated herein by reference.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The present invention concerns digital data processing software and/or hardware to quickly yet accurately determine if a given computer-readable record is represented, by exact match or pretty close match, in an existing collection of computer-readable records.
[0004] 2. Description of the Related Art
[0005] “Fuzzy matching” refers to a well known assortment of techniques to determine whether searched strings approximately match some given pattern string. These techniques are also known by other names such as approximate matching, inexact matching, fuzzy string searching, etc. Each implementation of fuzzy matching uses some similarity function, that is, an algorithm for determining whether the input and searched strings are similar to each other. One common similarity function is Levenshtein distance, and another is n-gram distance.
[0006] The commercial market already contains various products that employ fuzzy matching. One example is the Hunter software of Experian, which is intended to detect fraud in the customer acquisition process. Another example is found in the products of Identity Systems, formerly known as Search Software America, which provides various software products aimed at searching, finding, matching, and grouping identity data, regardless of structure, format, location, duplication, omissions or errors. Other examples are found in the products of IBM Entity Analytic Solutions (EAS), which aims to help organizations recognize the entities with which they are doing business. EAS is said to provide real time recognition and resolution, in context with existing business applications.
[0007] Although these systems provide certain benefits, Fair Isaac Corporation is interested in improving the performance and efficiency of fuzzy matching programs, since various Fair Isaac products do (or could) beneficially employ fuzzy matching. Fair Isaac has identified some areas of possible focus and some potential shortcomings of existing technology. For one, the computational complexity and cost associated with a brute-force, field by field fuzzy matching against each individual record in a reference database (e.g., a fraud file) is prohibitive in practice. Second, existing approaches can give misleading results when strong matches occur on weak data (such as the strong or identical match of a common first name such as “John”). Third, better control over the manner of fuzzy matching is desired. Fourth, the existing approaches are not as modular and easily extensible as some might like.
[0008] In view of these concerns, the existing fuzzy matching products are not completely adequate for all intended applications.
SUMMARY OF THE INVENTION
[0009] Broadly, the present disclosure concerns a new technique for fuzzy matching. This works to quickly yet accurately determine if a given computer-readable record is represented, by exact match or pretty close match, in a large collection of computer-readable records. Further tools may be provided to assess the character of the match.
[0010] The teachings of this disclosure may be implemented as a method, apparatus, logic circuit, storage medium, or a combination of these. This disclosure provides a number of other advantages and benefits, which should be apparent from the following description.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] FIG. 1 is a block diagram of the components and interconnections of a computer system.
[0012] FIG. 2 is a block diagram of a digital data processing machine.
[0013] FIG. 3 shows an exemplary storage medium.
[0014] FIG. 4 is a perspective view of exemplary logic circuitry.
[0015] FIG. 5 is a flowchart of an overall operating sequence.
[0016] FIG. 6 is a more detailed flowchart showing a filtering task in greater detail.
[0017] FIG. 7 is a diagram illustrating the relationship between various record sets.
DETAILED DESCRIPTION
A. Hardware Components & Interconnections
1. Overall Structure
[0018] One aspect of the present disclosure concerns a computer system ( 100 ) with various components that are configured to perform expedited, accurate fuzzy matching. Broadly, the system 100 includes a computer 106 , storage 120 , user input/output (I/O) 108 , and other computers 112 . Various interfaces 110 interconnect these components. Of course, other components may be added to these, but this architecture provides a starting point to illustrate the primary features of this disclosure.
[0019] Computer 106
[0020] Referring to FIG. 1 in greater detail, the computer 106 includes key generators 106 a - 106 b , a comparison engine 106 c , filter 106 d , analyzer 106 e , scorer 106 f , pruner 106 g , and controller 106 h.
[0021] The computer 106 and its subcomponents 106 a - 106 h are data processing entities, and these may be implemented by one or more hardware devices, software devices, a portion of one or more hardware or software devices, or a combination of the foregoing. Some examples are discussed below in FIGS. 2-4 . As one example, the computer 106 may be implemented by a computer workstation, mainframe computer, distributed computing arrangement, personal computer, server, or other computing machine appropriate to the implementation. In this example, the subcomponents 106 a - 106 h are implemented by processes, subroutines, object oriented programs, Java Applets, processing threads, machine code, or other software programming of the computer 106 hardware.
[0022] Broadly, each of the key generators 106 a - 106 b acts to receive an input string and compute an output key according to a predetermined computational formula. Under this formula, a given input string will always produce the same output key. However, several input strings (with certain types of similarities, as discussed below) will also produce the same output key. Therefore, the key generators 106 a - 106 b serve to “fuzzify” input, and provide a “many to one” mapping between input strings and keys. Under this regime, two input strings that produce the same output key must be similar in some ways. These similarities are prescribed by the details of the key computing formula.
[0023] In the illustrated example, the key generator 106 a applies one fuzzification formula, whereas the key generator 106 b applies a different formula. Alternatively, the key generator 106 b may be eliminated, in which case the computer 106 employs a single fuzzification formula. In still another alternative, the system 100 may include three, four, five, or any greater number of key generators. In one example, the system 100 may provide a different key generator for each different field (of current or anticipated records). Operational details of the key generators 106 a - 106 b are described in appropriate detail below, under the heading “Operation.”
[0024] The comparison engine 106 c produces an initial pool of candidate records by applying fuzzy matching to a given input record and records of a reference database 122 . In this operation, the engine 106 c employs the key generator 106 a to produce new keys for the input record, and as to the existing records ( 122 ) the engine 106 c uses previous output of the key generator 106 a stored in a key database 124 . Operational details of the comparison engine 106 c are described in appropriate detail below, under the heading “Operation.”
[0025] As mentioned above, the comparison engine 106 c produces a pool of candidate records. The filter 106 d acts to reduce or “filter” the candidate pool of records by applying various statistical analyses. Operational details of the filter 106 d are described in appropriate detail below, under the heading “Operation.”
[0026] The analyzer 106 e analyzes the candidate pool, providing one basis for other components to reduce the candidate pool even further as discussed below. In one embodiment, the analyzer 106 e applies a second stage of fuzzy matching, which employs keys previously prepared by the key generator 106 a or employs the key generator 106 b to produce completely new keys for both input record and reference records ( 122 ). Operational details of the analyzer 106 e are described in appropriate detail below, under the heading “Operation.”
[0027] The scorer 106 f applies a predetermined statistical analysis to the filtered, analyzed candidate pool in order to evaluate, score, rank, or otherwise assess these records relative to each other to relative to a predetermined standard. The scorer 106 f may be omitted, if appropriate to the intended application. For instance, the end user may not care about scoring. Or, scoring may be unnecessary if the computer 106 employs a powerful analyzer 106 e that limits the final record pool to manageable levels. Operational details of the scorer 106 f are described in appropriate detail below, under the heading “Operation.”
[0028] The pruner 106 g acts to reduce the candidate pool even further according to output from the analyzer 106 e and/or the scorer 106 f . Operational details of the pruner 106 g are described in appropriate detail below, under the heading “Operation.”
[0029] The controller 106 h directs the overall operation of the other components 106 a - 106 g , coordinating the various processing stages to produce a final result. The controller 106 h may perform other functions related to management of the computer 106 , such as managing peripheral hardware, performing functions unrelated to fuzzy matching, etc.
[0030] Interfaces 110
[0031] The system 100 includes one or more interfaces 110 to interface the computer 106 with peripheral hardware and/or software such as user I/O 108 , other computers 112 , and digital data storage 120 . Accordingly, the interfaces 110 include any of the following, as appropriate to serve the architecture and functionality described herein: telephone modems, cable modems, T1 interface, routers, Ethernet cards, IDE or EIDE units, satellite modems, wireless transceivers, USB interfaces, Fire wire ports, PS/2 ports, key ring networks, local area networks, wide area networks, infrared ports, etc.
[0032] User I/O 108
[0033] This component includes hardware and/or software for man-machine interface, such as video display, speakers, keyboard, digitizing pad, trackball, mouse, eye gaze tracking system, foot pedals, dials, buttons, touch screens, brain wave sensing machinery, and the like.
[0034] Other Computers 112
[0035] Optionally, the system 100 may be interfaced with one or more other computers 112 to receive input and/or provide output. As one option, the user I/O 108 may be omitted, with this user input/output occurring at one or more remote computes 112 . Or, the system may work free of user input/output, with input/output coming from external machines 112 instead of humans.
[0036] Storage 120
[0037] The storage 120 provides digital data storage, various embodiments of which are described below in greater detail under the heading “Storage Media.” The storage 120 includes a reference database 122 , key database 124 , and count database 126 . Any or all of the components 120 , 122 , 124 , 126 may be provided by relational databases, linked lists, tables, stacks, queues, or any collection of records that is structured and computer-readable, amenable for a computer program to consult and answer queries.
[0038] As mentioned below, one function of the system 100 is to determine if a given input record is represented in a collection of existing records. In this context, the reference database 122 provides the existing collection of records. The reference database 122 provides functional rows and columns representing records and fields, respectively. The database 122 may include virtually any type of data, such as a collection of current customers, past customers, perpetrators of fraud, recipients of a government benefit, etc. Or, apart from people, the database may represent other data concerning machine parts, vehicles, financial transactions, packets of communication, or any other tangible of intangible thing.
[0039] The key database 124 contains keys corresponding to given fields of each record in the reference database 122 . The “given” fields, namely those having keys, may be some or even all fields in the reference database 122 . There is not necessarily a one-to-one relationship between fields and keys, as several fields might be used to generate a single key, or a single field might by itself or in combination with other fields be used to generate several keys. The key database 124 may be incorporated into the reference database 122 , or it may be a separate database (as shown) linked to the reference database by appropriate pointer, reference, or other link ( 124 a ). In the presently illustrated example, the fields of the reference database 122 having keys are those of a set illustrated by item 702 in FIG. 7 . This is explained in greater detail below.
[0040] The count database 126 contains statistical data concerning (1) the values in the various fields of the reference database 122 , or (2) the occurrence of the keys in the key database 124 , or (3) both of these. The nature of the statistical data is discussed in greater detail below. The count database 126 may be incorporated into the databases 122 and/or 124 , or it may be a separate database (as shown) linked to the respective databases by appropriate pointer, reference, or other links ( 126 a , 126 b ).
2. Exemplary Digital Data Processing Apparatus
[0041] As mentioned above, data processing entities (such as the computer 106 and/or its various subcomponents 106 a - 106 h ) may be implemented in various forms.
[0042] Some examples include a general purpose processor, digital signal processor (DSP), application specific integrated circuit (ASIC), field programmable gate array (FPGA) or other programmable logic device, discrete gate or transistor logic, discrete hardware components, or any combination thereof designed to perform the functions described herein. A general purpose processor may be a microprocessor, but in the alternative, the processor may be any conventional processor, controller, microcontroller, or state machine. A processor may also be implemented as a combination of computing devices, e.g., a combination of a DSP and a microprocessor, a plurality of microprocessors, one or more microprocessors in conjunction with a DSP core, or any other such configuration.
[0043] As a more specific example, FIG. 2 shows a digital data processing apparatus 200 . The apparatus 200 includes a processor 202 , such as a microprocessor, personal computer, workstation, controller, microcontroller, state machine, or other processing machine, coupled to a digital data storage 204 . In the present example, the storage 204 includes a fast-access storage 206 , as well as nonvolatile storage 208 . The fast-access storage 206 may be used, for example, to store the programming instructions executed by the processor 202 . The storage 206 and 208 may be implemented by various devices, such as those discussed in greater detail in conjunction with FIGS. 3 and 4 . Many alternatives are possible. For instance, one of the components 206 , 208 may be eliminated; furthermore, the storage 204 , 206 , and/or 208 may be provided on-board the processor 202 , or even provided externally to the apparatus 200 .
[0044] The apparatus 200 also includes an input/output 210 , such as a connector, line, bus, cable, buffer, electromagnetic link, network, modem, transducer, IR port, antenna, or other means for the processor 202 to exchange data with other hardware external to the apparatus 200 .
3. Storage Media
[0045] As mentioned above, various instances of digital data storage may be used, for example, to provide storage used by the system 100 ( FIG. 1 ), to embody the storage 204 and 208 ( FIG. 2 ), etc. Depending upon its application, this digital data storage may be used for various functions, such as storing data, or to store machine-readable instructions. These instructions may themselves aid in carrying out various processing functions, or they may serve to install a software program upon a computer, where such software program is then executable to perform other functions related to this disclosure.
[0046] In any case, the storage media may be implemented by nearly any mechanism to digitally storage machine-readable signals. One example is optical storage such as CD-ROM, WORM, DVD, digital optical tape, disk storage 300 ( FIG. 3 ), or other optical storage. Another example is direct access storage, such as a conventional “hard drive”, redundant array of inexpensive disks (“RAID”), or another direct access storage device (“DASD”). Another example is serial-access storage such as magnetic or optical tape. Still other examples of digital data storage include electronic memory such as ROM, EPROM, flash PROM, EEPROM, memory registers, battery backed-up RAM, etc.
[0047] An exemplary storage medium is coupled to a processor so the processor can read information from, and write information to, the storage medium. In the alternative, the storage medium may be integral to the processor. In another example, the processor and the storage medium may reside in an ASIC or other integrated circuit.
4. Logic Circuitry
[0048] In contrast to storage media that contain machine-executable instructions (as described above), a different embodiment uses logic circuitry to implement processing features such as the computer 106 and/or any one or more of components 106 a - 106 h.
[0049] Depending upon the particular requirements of the application in the areas of speed, expense, tooling costs, and the like, this logic may be implemented by constructing an application-specific integrated circuit (ASIC) having thousands of tiny integrated transistors. Such an ASIC may be implemented with CMOS, TTL, VLSI, or another suitable construction. Other alternatives include a digital signal processing chip (DSP), discrete circuitry (such as resistors., capacitors, diodes, inductors, and transistors), field programmable gate array (FPGA), programmable logic array (PLA), programmable logic device (PLD), and the like.
[0050] FIG. 4 shows an example of logic circuitry in the form of an integrated circuit 400 .
B. Operation
[0051] Having described the structural features of the present disclosure, the operational aspect of the disclosure will now be described. The steps of any method, process, or algorithm described in connection with the embodiments disclosed herein may be embodied directly in hardware, in a software module executed by hardware, or in a combination of the two.
1. Introduction
[0052] A basic implementation of fuzzy matching would be to query every field, or collection of fields, of every single record in the reference database 122 , and compute a fuzzy match against every field, or collection of fields, of an input record using any one of various known algorithms. One issue with such an implementation is that it scales poorly, and becomes impractical once the reference database reaches a few ten thousand records. To improve on this, the present disclosure performs a pre-filter of the records that is itself fuzzily compared.
[0053] The present implementation of fuzzy matching pre-computes a condensed key (or signature or token or other computational output) of the actual reference record fields, or collection of fields, to be matched, and stores these pre-computed keys (herein termed the “fuzzed-up fields” even in the case of collections of fields being used to generate the keys) in a separate table ( 124 ). Instead of then having to query the complete reference database 122 and compute a fuzzy match on each record, the computer 106 (in one embodiment) can reduce the list of match candidates from the reference database 122 to only those records that have at least one pre-fuzzed-up field, or collection of fields, (from the key database 124 ) exactly equal to the corresponding fuzzed-up field, or collection of fields, of the application to be matched. Other alternatives to this technique to reduce the list of match candidates are disclosed. Nevertheless, this gain in computational efficiency contributes to making the problem computationally tractable.
[0054] Additionally, the computer 106 can store (along with the fuzzed-up fields) the frequency with how often they occur in the data, since rare keys that match provide more information than matching of a common key. This data ( 126 ) is then available to optionally compute a weighted fuzzy match score by considering all fields used for the match, and summing up the field-level match results.
[0055] In this description, there are widespread references to the act of computing keys from record fields. It is emphasized that this disclosure contemplates, but does not require, a one-to-one relationship between fields and keys. For instance, several fields might be used to generate a single key. Or, a single field might by itself or in combination with other fields be used to generate several keys. Nevertheless, for ease of reading (but without any intended limitation), the following description references the computation of keys from record fields in terms of the basic case, where there is a one-to-one relationship.
2. Overall Sequence of Operation
[0056] Introduction
[0057] FIG. 5 shows one example of a fuzzy matching sequence 500 . For ease of explanation, but without any intended limitation, the example 500 is described in the specific context of the system 100 ( FIG. 1 ).
[0058] Select Fields
[0059] In step 502 , system architects select which fields of the reference database 122 will have pre-computed, pre-stored keys. Pre-computing keys for various fields of the reference database 122 will help speed fuzzy matching operations performed later. The designers in step 502 may select any fields that will be likely involved in fuzzy matching. To cite a simplified example, one set of selected fields may be: first name, last name, social security number, street name, city, street address, and home telephone. In FIG. 7 , these fields (for which keys will be pre-computed and pre-stored) are illustrated by the set 702 . More restrictive sets 706 , 704 are used later in the sequence 500 , as discussed below.
[0060] Compute Keys
[0061] For ease of discussion, records represented in the reference database 122 will be referred to as “reference records.” In step 504 , the controller 106 h instructs the key generator 106 a to compute one key for each of the fields selected in 502 (i.e., the fields 702 ), for each record in the reference database 122 . In the simplified example given above, step 504 starts with a first record in the reference database 122 , and computes a key for each value of first name, last name, social security number, street name, city, street address, and home telephone fields. Step 504 re-performs this operation for every remaining record in the reference database 124 . The controller 106 h or key generator 106 a stores the computed keys in the key database 124 .
[0062] As an alternative, instead of using the key generator 106 a for all fields, the controller 106 h may use different key generators for different fields or collections of fields.
[0063] As a further alternative, instead of performing step 502 on an existing reference database, step 502 may be performed from the beginning with an empty reference database 122 , whenever new records arrive for storage in the reference database 124 . Or, step 502 may be performed on the set of records in the reference database 122 as of a certain date, and then repeated in real time whenever new records arrive.
[0064] In order to compute the keys, the key generator 106 a may use any computational formula such that each key is produced exclusively by a set of input values having certain similarities to each other. Thus, there is a many-to-one mapping from potential input strings to keys. One example of computational formula is the well known Soundex phonetic algorithm (“Russel Soundex”), which is addressed in various issued U.S. patents, technical journal articles, and at least one book. Other examples include the Celko Improved Soundex algorithm, Metaphone algorithm, Double-Metaphone, Daitch-Mokotoff (D-M) Soundex, etc. A further example is the well known NYSIS algorithm developed by the New York State Identification and Intelligence System as an improvement to Soundex. In addition or instead of these, the key generator 106 a may employ any other key generating formula based on phonics, numerical, double metaphonics, etc. Optionally, different key generators (such as 106 a - 106 b ) may be invoked to vary the key formula for different fields. For example, one of key generators 106 a - 106 b may act to simply copy-over complete, raw, or original data from the reference record into the key database 124 in the case of certain specified fields. It may prove helpful, for example, to have such field values available for later processing (as discussed below). Also, there may be fields containing unique data (such as social security numbers) for which is it unnecessary or undesirable to compute keys.
[0065] Optionally, at this time, step 505 may statistically analyze the reference database 122 in order to compute and store count data in the database 126 . In this regard, the controller 106 h in step 505 computes statistical data concerning the values in the various fields of the reference database 122 , and/or the keys in the database 124 . In the case of the reference database 122 , this statistical data includes a statistical breakdown of field values, for example by count (number of occurrences), frequency of occurrence, percentile, or other assessment of values in some or all fields. This data may be broken down further by field. For example, the count database 126 may indicate that a given field value (“Oslo”) occurs one hundred times in the “City Name” field of the database 122 , or that “Oslo” occurs in the “City Name” field of twenty five percent of all records in the reference database 122 . In the case of the key database 124 , this statistical breakdown includes a statistical breakdown of the keys. For example, the count database 126 may indicate that a given key occurs one thousand times in the database 124 , or that the given key constitutes forty percent of all keys in the database 124 , or that the given key occurs four hundred times as to a given reference field.
[0066] Although task 505 may be performed from time to time in batch, alternatives are to calculate statistical data from the beginning with an empty reference database 122 , calculate statistical data whenever new records arrive for storage in the reference database 124 , or perform statistical analysis on a set of records in the reference database 122 as of a certain date, and then repeat in real time for new records that arrive.
[0067] Arrival of Input Record
[0068] In step 506 , the computer 106 (and more particularly, the controller 106 h ) receives a record to evaluate. For ease of explanation, this is interchangeably referred to as the “given” record or “input” record. This record may come from the user I/O 108 , for instance if the record is entered or submitted or identified by a human user such as a customer, system administrator, software user, or other person. Alternatively, the record may be submitted or entered or identified by a remote computer 112 . As another alternative, the computer 106 itself may identify the record. For example, users may enter new records into a cache (not shown), and the computer 106 takes up cached records for processing in order of entry or another order. Or, the computer 106 may self-select records from the reference database 122 for screening or evaluation, unrelated to input of any new record. Step 506 may observe any of these approaches, or a combination.
[0069] Fuzzy Matching
[0070] In step 507 - 508 , the computer 106 performs fuzzy matching upon the input record. In one sense, the pre-computation of keys (from step 504 ) may be considered an early party of fuzzy matching, too. In step 507 , responsive to receiving the input record ( 506 ), the controller 106 h directs the key generator 106 a to compute keys for fields of the given record 507 . To expedite the overall process 500 , the key generator 106 a only computes keys for a limited set of fields of the given record. For example, step 507 may limit key computation to first name, last name, and social security number fields. FIG. 7 illustrates this limited set at 704 , and shows that this set 704 is a smaller subset of the entire set of fields ( 702 ) for which keys were computed and stored ( 504 ) in the key database 124 . By limiting fuzzy matching to the field set 704 (instead of the entire set 702 ) this expedites the overall process 500 .
[0071] In step 508 , the comparison engine 106 c compares the keys for the input record (computed in step 507 ) with the corresponding, pre-computed keys (stored in 124 ) of each reference record. In conformance with the limited fuzzy matching strategy, and since step 507 only computed keys for a limited set ( 704 ) of fields, step 508 only compares keys of the limited set 704 of fields as between the given record and the reference records. In the previously introduced example, step 508 will compare the keys for the given record's first name, last name, and social security number fields to each reference record's respective keys for those same fields, looking to see if the keys match identically.
[0072] If at least one key of the given record matches a key for the same field of the reference record, that reference record is added to a “candidate pool.” For example, if the given record's key for last name matches a particular reference record's key for last name, the reference record is added to the candidate pool. In one embodiment, where each reference record is given a unique record number in the database 122 , addition of a record to the candidate pool may be carried out by recording the record's number in a list.
[0073] Filtering
[0074] In step 509 , the filter 106 d hones the candidate pool by removing records from the candidate pool whose fuzzy match with the input record is weak (according to predetermined criteria). Broadly stated, this is carried out by statistically analyzing the nature of the matches found in 508 . For greater speed, this process utilizes the statistical data stored in the count database 126 . Filtering ( 509 ) is discussed in greater detail below, with reference to the sequence 600 ( FIG. 6 ).
[0075] Analysis
[0076] After filtering (step 509 ), the next step in the process 500 is to analyze the candidate pool ( 510 ). Broadly, in step 510 the analyzer 106 e performs more comprehensive fuzzy matching than was conducted in steps 507 - 508 . Now that the process 500 has narrowed the reference records down to a candidate pool (step 508 ) and further filtered that pool (step 509 ), it is possible to perform more comprehensive or comprehensive fuzzy matching without great sacrifice in computational effort. Thus, in step 510 the analyzer 106 e performs fuzzy matching as between the input record and the records of the filtered and pruned candidate pool. Renewed fuzzy matching ( 510 ) may be carried out in various ways, two of which are described as follows.
[0077] Step 513 describes one exemplary technique. Here, the last part of the previously conducted fuzzy matching is repeated, but applied to a broader set of fields. In other words, and as compared to the fuzzy matching of steps 507 - 508 (based upon fields of the set 704 shown in FIG. 7 ), the renewed fuzzy matching of step 513 involves a greater number of fields (for example, the set 706 or even the set 702 ). Advantageously, then, the field set 706 is substantially greater than the field set 704 . In the present example, the field set 706 includes first name, last name, social security number, street name, and city. Fuzzy matching of step 513 employs the same keys computed in steps 504 , 507 along with additional keys that must be computed for the input record (for fields not having keys computed in 507 but are part of the fuzzy matching 513 ). For computing these added keys, the key generator 106 a is used.
[0078] In contrast to step 513 , steps 511 - 512 describe an alternative technique for technique. This technique employs the key generator 106 b instead of the key generator 106 a . For each record in the filtered pool, step 511 retrieves the complete, original, or raw record from the reference database 122 (or at minimum, the complete, original, or raw values of the fields 706 ). Then, step 512 computes new keys upon these field and the corresponding fields of the input record. Using these, step 512 performs fuzzy matching on all fields of the field set 706 , as between the input record and the records of the filtered candidate pool. In this example, then, the approach of steps 511 - 512 is enhanced relative to the earlier fuzzy matching (steps 504 , 507 , 508 ) because it considers a greater number of fields ( 706 or even 702 ) than the field set ( 704 ) used in steps 504 , 507 , 508 . Additionally, the approach of steps 511 - 512 is further enhanced because it employs an enhanced fuzzy matching formula, namely that of the key generator 106 b rather than 106 a . As to the fuzzy matching formula, this may use a similar key formula as discussed before (e.g., Soundex, NYSIS, etc.) but with different resolution, bit sampling, comparison or combination of multiple formulas, etc. Alternatively, the fuzzy matching formula of step 512 may conduct analysis unrelated to keys, with one example being the Levenshtein edit distance.
[0079] Instead of using the key generator 106 b for all fields in step 512 , the following is one alternative. As an example, this may be used in the embodiment (described above) where step 504 used different key generators for different fields or collections of fields. Like step 502 , step 512 may use different key generators for different fields. However, in this example, the set of key generators used here is different than the set of key generators used in step 514 .
[0080] Ultimately, step 510 produces a list of records referred to as a final candidate pool.
[0081] Scoring
[0082] Next, in step 514 the scorer 106 f scores the candidate pool according to the analysis of step 510 . Broadly, the scorer 106 f analyzes records of the analyzed candidate pool to evaluate, score, rank, or otherwise assess these records relative to each other or to relative to a predetermined standard. In one example, scoring may consider factors such as inverse term frequency, i.e., terms that occur more often are given a lower score contribution than terms that occur infrequently with more significance. As a different example, step 514 may act to compute a weighted fuzzy match score by considering all fields used for the match, and summing up the field-level match results. Scoring may be implemented using these, or a combination of these, or a variety of different known techniques described in the numerous patents and patent publications of Fair Isaac Corporation. Optionally, step 514 may also produce a reason code, indicating an explanation for a given record's score.
[0083] Step 514 is optional, however, and may omitted without departing from this disclosure. As a further alternative, scoring 514 may performed at a different occasion in the sequence 500 . One example is between steps 508 - 509 , in which case operation 509 may utilize scores in performing filtering. As another example, scoring may be performed between steps 509 - 510 , or during step 510 . Thus, step 510 may utilize scoring information in performing its analysis.
[0084] Pruning & Output
[0085] After the optional scoring (step 514 ), the sequence 500 presents two options 514 a - 514 b . In option 514 a , the pruner 106 g prunes the candidate pool (step 515 ) according to output from the analysis (step 510 ) and scoring (step 514 , if applicable). To provide some examples, some examples of pruning include setting a score threshold and removing all candidates receiving a score below it, or setting several score thresholds to be used based on which fields did match, or limiting the absolute number of candidates and removing all but the highest scoring ones in case this number was exceeded, or any combination of these, or no pruning at all.
[0086] After step 515 , the controller 106 h in step 516 provides an output identifying the records of the pruned pool and/or the computed scores of the pruned records. Also in step 516 , the controller 106 h renders this output to a site such as the user I/O 108 or another computer 112 . As an alternative, the controller 106 h may cache the output for retrieval on demand by a user, remote machine, or automated process.
[0087] In contrast to option 514 a , in option 514 b the sequence 500 skips step 514 a and performs step 516 as discussed above, only with regard to the un-pruned candidate pool.
3. Filtering
[0088] FIG. 6 shows one exemplary process 600 for conducting filtering as per step 509 ( FIG. 5 ). The process 600 is carried out by the filter 106 d . The process 600 works by “picking” certain candidates to retain in the candidate pool and excluding the rest.
[0089] As mentioned above, steps 507 - 508 perform fuzzy matching upon the input record as to the reference records. If at least one key of the input record matches a key for the same field of the reference record, that reference record is added to the candidate pool. For example, if the given record's key for last name matches a particular reference record's key for last name, the reference record is added to the candidate pool. Accordingly, a reference record may be qualified to enter the candidate pool for numerous reasons, i.e., multiple fields that demonstrate a fuzzy match with a corresponding field of the input record.
[0090] With this in mind, step 602 begins with a sub-group of the candidate pool. Namely, step 602 begins with a set of all reference records that entered the candidate pool (step 508 ) due to a fuzzy match occurring in a first field. The first field may be selected on any appropriate basis, such as arbitrarily, field order, alphabetic order of field names, etc. The field under discussion at any one iteration of the process 600 is referred to as the “current” field (for brevity the term “current field” is used even in case of a collection of fields).
[0091] Next, step 604 considers frequency data for the current field of the input record. As mentioned above, the sub-group of candidates under discussion qualified for the candidate pool for at least the following reason—the current field of the reference record was a fuzzy match to the current field of the input record. This is why the current field of the input record is examined in step 604 . More particularly, step 604 references the database 126 to determine the count of the data from the current field of the input record.
[0092] For example, where the current field is a “City” field, step 604 may reveal that the current field of the input record is “Oslo” and this occurs in 1,263 records of the reference database 122 . If the input record also qualified for the candidate pool based on a fuzzy match of another field, or another collection of fields, this is irrelevant for the present analysis.
[0093] Next, step 606 asks whether the number from step 604 is greater than a prescribed threshold (“NMAX”). If so, step 607 refrains from “picking” the current sub-group of reference records. In the present example, NMAX is set to one thousand. Thus, step 606 is satisfied in the present example because Oslo occurs in over one thousand reference records.
[0094] In a different example, if the threshold (NMAX) were set to 5,000, then step 606 would not be satisfied, and the process 600 would advance to step 608 . Step 608 asks whether the number from step 604 is less than a second threshold (NKEEP). The threshold NKEEP is set sufficiently low (e.g., fifty records) so as to identify highly meaningful matches. Thus, the filter gives precedence to less common matches, which are statistically more relevant. In the present case, step 608 is not satisfied since Oslo occurs in more than fifty records. Thus, step 612 (discussed below) is performed. On the other hand, if Oslo occurred in less than fifty records, step 608 would be satisfied, and step 610 would occur. Step 610 “picks” the current sub-group of reference records. The utility of “picking” record groups is discussed in greater detail below.
[0095] As mentioned above, if step 608 is not satisfied, then step 612 occurs. Step 612 reduces the candidate pool belonging to the current field given that the size of this pool is larger than NKEEP but smaller or equal to NMAX. This reduction may be based on rules or statistical analysis, may be random, or a combination thereof. Some examples of this include:
(a) Random selection of NKEEP many records, (b) Sort the records in increasing order by how many other fields have matched as well. (c) Assuming that all fields are sorted by a preset importance value, sort the records from the pool by whether they match also in the most important other field, or in the second-most important other field, etc. (d) Using pre-assigned weights for each field, for each record in the candidate pool compute a match score by summing the weights of those fields that match. Then sort the candidate records by their achieved sum of weights. (e) Require that the candidate records also match at least a certain number (e.g., one or two) of other fields. (f) Require that the candidate records also match a specific selection of (e.g., one or two) other fields.
For methods (b) through (f), take the top NKEEP many records. Tie breaks may be resolved randomly, or with the use of some of the other rules.
[0102] After any of steps 607 , 610 , 612 a , or 612 b complete, step 616 asks whether there are any remaining candidate sub-groups to consider. Namely, step 616 asks whether the process 604 - 612 b has progressed through all fields, or all collection of fields, and corresponding keys used in step 508 . If not, step 618 advances to the next candidate group (based upon the next field of fuzzy matching), and then re-performs step 604 on this basis.
[0103] On the other hand, when step 616 finds that all candidate groups have been considered, step 620 carries out a filtering operation. Namely, step 620 creates a filtered candidate pool consisting of those reference records of the candidate pool that were “picked” in steps 610 or 612 a . The process 600 ends in step 622 .
4. Applications
[0104] The disclosed system 100 and processes 500 , 600 may be applied in a number of different contexts. Without any intended limitation, the following is a sampling of different applications.
[0105] In one example, these techniques are employed in fraud screening. During processing of credit applications, for example, there is usually some kind of fraud screening. Credit applications are often compared against previously identified frauds. Since the fraudsters are aware of this customary check, they tend to vary their application data slightly, maybe change a spelling here or there, or change some components of the address or other information. The challenge is then to still match the application against the fraud file in a non-exact, or fuzzy, manner. Of course, the matching of applications does not have to be limited to matching against the previously identified fraud file, one can also match against previous applications, or the customer master file. In fact, fuzzy matching does not necessarily concern applications, but could be used for any kind of string data.
[0106] In another context, these techniques may be employed when people apply for government assistance, to conduct same entity analysis to see if they are already receiving assistance or another disqualifying benefit. In another context, a corporation may employ the system 100 to periodically conduct redundancy analysis in its databases, by recognizing records that (despite trivial differences) are really represent the same person or entity. For instance, a club or association may reduce magazine mailing costs by periodically screening its subscription list to identify cases where the same people mistakenly appear twice, causing two magazines to be sent to the same person. Furthermore, the system 100 is useful in numerous computing applications that seek to perform some type of same entity analysis.
C. Other Embodiments
[0107] While the foregoing disclosure shows a number of illustrative embodiments, it will be apparent to those skilled in the art that various changes and modifications can be made herein without departing from the scope of the invention as defined by the appended claims. Accordingly, the disclosed embodiment are representative of the subject matter which is broadly contemplated by the present invention, and the scope of the present invention fully encompasses other embodiments which may become obvious to those skilled in the art, and that the scope of the present invention is accordingly to be limited by nothing other than the appended claims.
[0108] All structural and functional equivalents to the elements of the above-described embodiments that are known or later come to be known to those of ordinary skill in the art are expressly incorporated herein by reference and are intended to be encompassed by the present claims. Moreover, it is not necessary for a device or method to address each and every problem sought to be solved by the present invention, for it to be encompassed by the present claims. Furthermore, no element, component, or method step in the present disclosure is intended to be dedicated to the public regardless of whether the element, component, or method step is explicitly recited in the claims. No claim element herein is to be construed under the provisions of 35 USC 112, sixth paragraph, unless the element is expressly recited using the phrase “means for” or, in the case of a method claim, the phrase “step for”.
[0109] Furthermore, although elements of the invention may be described or claimed in the singular, reference to an element in the singular is not intended to mean “one and only one” unless explicitly so stated, but shall mean “one or more”. Additionally, ordinarily skilled artisans will recognize that operational sequences must be set forth in some specific order for the purpose of explanation and claiming, but the present invention contemplates various changes beyond such specific order.
[0110] In addition, those of ordinary skill in the relevant art will understand that information and signals may be represented using a variety of different technologies and techniques. For example, any data, instructions, commands, information, signals, bits, symbols, and chips referenced herein may be represented by voltages, currents, electromagnetic waves, magnetic fields or particles, optical fields or particles, other items, or a combination of the foregoing.
[0111] Moreover, ordinarily skilled artisans will appreciate that any illustrative logical blocks, modules, circuits, and process steps described herein may be implemented as electronic hardware, computer software, or combinations of both. To clearly illustrate this interchangeability of hardware and software, various illustrative components, blocks, modules, circuits, and steps have been described above generally in terms of their functionality. Whether such functionality is implemented as hardware or software depends upon the particular application and design constraints imposed on the overall system. Skilled artisans may implement the described functionality in varying ways for each particular application, but such implementation decisions should not be interpreted as causing a departure from the scope of the present invention.
[0112] The previous description of the disclosed embodiments is provided to enable any person skilled in the art to make or use the present invention. Various modifications to these embodiments will be readily apparent to those skilled in the art, and the generic principles defined herein may be applied to other embodiments without departing from the spirit or scope of the invention. Thus, the present invention is not intended to be limited to the embodiments shown herein but is to be accorded the widest scope consistent with the principles and novel features disclosed herein. | A computer-implemented technique for fuzzy matching. This works quickly yet accurately to determine if a given computer-readable record is represented, by exact match or pretty close match, in a large collection of computer-readable records. Further tools may be provided to assess the character of the match. | 6 |
This is a continuation of application Ser. No. 08/344,061, filed Nov. 23, 1994, now abandoned.
FIELD OF THE INVENTION
This invention relates to a device for the transmission of one-way torque and in particular to a device which may readily be moulded from plastics and can transmit high driving forces.
BACKGROUND
Devices for transmission of one-way torque are well known, common examples include a socket wrench and the winding mechanism of a clockwork motor, watch, clock etc. Generally such devices comprise at least one metal part and a biasing spring to bias a pawl in engagement with the teeth of a ratchet wheel.
WO90/13328 discloses a dry powder inhalation device comprising a housing defining a chamber in communication with a patient port in the form of a mouthpiece or nasal adaptor, and an elongate carrier bearing a powdered medicament, the device being constructed and arranged such that areas of predetermined size of the elongate carrier may sequentially be exposed within the chamber, the device comprising one or more air inlets such that when a patient inhales through the patient port an air flow is established from the air inlet(s) to the patient port through the chamber such that particles of the powdered medicament of respirable size from said exposed area of the elongate carrier are entrained within the air flow.
The elongate carrier is preferably in the form of a tape having a surface with grooves, pores, apertures or other embossed features which contain particles of medicament. The tape is conveniently wound on a supply spool and preferably contained within a cassette having a supply and take-up spool. The tape may contain many doses of the drug e.g. 200 doses.
In use, areas of the tape are sequentially advanced into the chamber to dispense the medicament contained within that area of tape. It is essential that the tape is advanced in well defined steps from the supply to the take-up spool to facilitate accurate, reproducible dosing and to prevent drug wastage. The advancement of the tape is conveniently facilitated by pivotal movement of a lever, either in a similar manner to the winder lever of a camera, or more preferably in the form of a mouthpiece cover, such that the tape is automatically advanced when the patient opens the cover. Such arrangements require an efficient one-way drive providing precisely controlled advancement and so that closure of the cover causes no movement of the tape.
The requirements of such a drive mechanism for use in an inhaler are manifold. It is desirable that the mechanism be cheap, preferably injection moulded in a minimum number of plastic parts. The device should be compact and lightweight, able to transmit large drive forces in relation to the torque needed to reverse the mechanism, capable of achieving low levels of variation in any lost motion, reliable, able to withstand temperatures of -20° C. to +70° C. for several hours without creeping or stress relaxing when "parked" in any configuration, able to resist wear and tear after prolonged usage (several thousand operations in each direction), reasonably immune to dirt or powder ingress, cheap to assemble, and quiet in operation.
The invention has been made with the above points in mind.
SUMMARY OF THE INVENTION
According to the present invention there is provided a device for the transmission of one-way torque comprising:
an outer annular member having a plurality of radially inwardly projecting teeth each comprising a driving surface and a cam surface,
a shaft concentrically mounted with respect to the outer annular member, the shaft comprising a plurality of drive elements each having a driving surface and a cam surface, whereby:
rotation of the shaft or outer annular member in its driving direction causes engagement of a driving surface of at least one drive element with a driving surface of at least one tooth thereby resulting in joint rotation of the shaft and outer annular member and
rotation of the shaft or outer annular member in its non-driving direction causes engagement of the cam surface of at least one drive element with the cam surface of at least one tooth resulting in additional relative movement, substantially radially, between said drive element and tooth thereby preventing rotational movement being transmitted between the shaft and outer annular member,
said engagement of the driving surfaces and the cam surfaces not requiring the presence of spring biasing means.
The invention also extends to an inhaler having an elongate carrier bearing powdered medicament and an advancement means for moving the carrier to position an area of the carrier in a predetermined place for dispensing medicament, the advancement means comprising a springless device for the transmission of one-way torque as described above.
In accordance with one embodiment of the invention the drive elements are mounted on the shaft in a manner allowing substantially radial movement. Conveniently the device comprises two drive elements which are interconnected to form a slider or reciprocating pawl, which is mounted in a channel extending substantially diametrically across the shaft, the slider or pawl being free to reciprocate along its length. The driving surfaces of the teeth and slider or pawl are preferably substantially radial and the length of the slider or pawl allows engagement of only one of the drive elements at a time.
In accordance with a further embodiment of the invention the drive elements are fixed to the shaft in the form of radially outwardly extending teeth each having a driving surface and a cam surface and the radially inwardly projecting teeth of the outer annular member are substantially radially movable between driving and non-driving positions. The movable teeth are conveniently integrally formed with a wedging element which wedges between the drive elements on the shaft and an inner surface of the outer annular member to transmit the drive.
Either the shaft or the outer annular member may be connected to a drive means e.g. lever, inhaler cover etc. Preferably the drive means is connected to the shaft. The outer annular member may be axially connected to a spool etc. or may comprise gear teeth moulded onto its radially outer surface which may be used to drive a spool etc. via a gear wheel.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention will now be described with reference to the accompanying drawings in which:
FIG. 1 represents a cross-section through a device in accordance with the invention.
FIG. 2 represents a cross-section through a modified device of the type shown in FIG. 1,
FIG. 3 represents an alternative construction of shaft and drive element suitable for use in a device of the invention,
FIGS. 4 and 5 represent exploded upper and lower views of a further embodiment of the invention,
FIGS. 6 and 7 represent cross-sections through the device of FIGS. 4 and 5 during the drive and return cycles respectively.
FIG. 8 represents a diagrammatic cross-sectional view of an inhaler suitable for use with a torque transmission device according to the invention,
FIG. 9 represents a diagrammatic cross-sectional view of another inhaler suitable for use with a torque transmission device according to the invention, and
FIG. 10 represents a diagrammatic cross-sectional view of another configuration of the inhaler shown in FIG. 9.
DETAILED DESCRIPTION
FIG. 1 shows a cross-section through a transmission device of the invention comprising an outer annular member (2) having 16 inwardly projecting teeth (4) each comprising a driving surface (6) and a cam surface (8). The annular member (2) may be a gear wheel having gear teeth (not shown) projecting radially outwardly.
A shaft (10) is concentrically mounted within the outer annular member (2) and is associated with two drive elements (12,14) which are joined to form a slider (16). Each drive element (12,14) comprises a driving surface (18,20) and a cam surface (22,24). The slider (16) is located within channel (26) within the shaft (10) and is free to reciprocate in the radial direction. In order to minimise friction between the slider (16) and the walls of the channel the surface areas in contact are reduced by the presence of rounded projections (28) extending from the wall of the channel (26). It will be appreciated such projections may equally well be present on the slider (16). The shaft (10) may be attached to a lever (not shown) e.g. the pivoting cover of an inhaler, to cause rotional movement of the shaft (10).
When the shaft (10) is rotated clockwise the driving surface (18) of the drive element (12) will engage the driving surface (6) of a tooth (4) causing the outer annular member (2) to be rotated through the same angle. If the rotation of the shaft (10) is reversed the slider (16) will be caused to reciprocate as the cam surface (22) of the drive element (12) will engage the cam surface (8) of a tooth causing radial movement of the slider (16) in one direction and thereafter the cam surface (24) of the drive element (14) will engage the cam surface (8) of a different tooth (4) causing radial movement of the slider (16) in the opposite direction. Thus no driving force will be transmitted to the annular outer member (2) and the shaft is free to rotate. Thus, this embodiment of the invention is effectively a form of escapement with the slider (16) reciprocating to allow the teeth (4) to escape past it at alternate ends.
Due to the shallow tooth angle of the teeth (4) there is more force tending to cause reciprocation of the slider (16) than back rotation of the outer annular member (2). In practice, there is likely to be enough friction in any gear train etc. of which the outer annular member may form a part, and low enough friction of the slider in its channel, to ensure that back rotation of the outer annular member does not occur. One of the major advantages of inhaler drive mechanisms according to this embodiment has been found to be the complete lack of back rotation of the outer annular member (2).
Another advantage is the consistency of the lost motion in the device of FIG. 1. Consider a back rotation (free wheeling) action of the shaft followed by a reversal i.e. driving action. If the reversal occurs at a random position, then the next driving point will be reached after between about 0° and 360°/32 of lost motion, i.e. there will be a random amount of lost or wasted motion of up to approximately 11°. Obviously more teeth (4) on the outer annular member (2) would reduce the maximum possible lost motion, but at the expense of requiring smaller teeth with less strength. Consider reciprocation of the shaft between two given positions, as would happen if the shaft were fixed to an inhaler mouthpiece cover which was being repeatedly opened and closed by a patient, for example. Although there would still be lost motion, it would be constant, as each driven tooth would be contacted, and subsequently left, at consistent positions. The approximately 11° angle between adjacent drive positions provides an estimation of the tolerance of the system to variations in shaft freewheeling angle. If the shaft is rotated by 5° less than usual in the freewheeling direction e.g. the inhaler mouthpiece cover is not completely closed, then the next shaft drive cycle, linked to the mouthpiece cover opening, will be 5° shorter than usual, but the 5° will be subtracted from the lost motion, so that the driven rotation of the outer annular member, causing advance of drug coated tape, will be the usual full amount.
A further advantage of the device is the lack of potential creep of such a plastic ratchet mechanism. Most known ratchets require springs of some nature for them to operate correctly. The choice is usually either a metal spring, which can be expensive, hard to produce accurately to small tolerances, and may cause substantial wear of other fine plastics parts, or a plastics spring which will suffer from creep or stress relaxation if parked under any significant loading force at elevated temperatures. Most simple fine scale plastics ratchet mechanisms are unable to ensure that parking cannot occur with a spring in a loaded configuration and leaving most such mechanisms in a hot car in bright sunshine, a few hours at 5° C., for example, would be sufficient for enough creep to occur to prevent the ratchet functioning properly again. The device of FIG. 1 has no spring function, however, so is not susceptible to such a creep problem.
In an alternative embodiment (not shown) of the device of FIG. 1, eight teeth inside the outer annular member were present, each deeper. This arrangement thus provides larger teeth of higher strength and greater tolerances. Although the device has fewer drive positions, eight teeth and two slider ends giving sixteen drive positions, it is possible to be more certain which will engage if the shaft is rotated by an angle which varies slightly, i.e. there is a large tolerance on the freewheeling angle. For example, consider a lever attached to the shaft being reciprocated by around 165° each time. Each stopping point corresponds to 360°/16=22.5°, so that 165° is equivalent to seven times the angle between drive positions plus 7.5° slack. In other words, there will be approximately 7.5° of wasted motion of the shaft each time, but exactly 7×22.5°=157.5° of outer annular member rotation, i.e. the drive should theoretically provide a consistent 157.5° one-way rotation of the outer annular member as the shaft is reciprocated repeatedly by approximately 165°. Tests of this device showed the expected mean rotation of the outer ring, with a standard deviation of the rotation angle of less than one and a half degrees.
Whilst the device of FIG. 1 does not require a spring biasing means for operation since the slider is free to move entirely under the influence of the teeth (4) it is possible to provide a bistable biasing action which causes a snap action during radial movement. FIG. 2 shows the slider (16) provided with two plastic spring wings (30), the ends of which are retained within recesses (32). The wings (30) may be formed integrally with the slider (16). The wings (30) have a bistable action tending to move the slider (16) towards one of its ends or the other with a snap action. Full engagement of a drive element at the end of the slider with a tooth (4) will thus tend to be more assured, reducing the possibility of tip wear of the slider due to large torques being transmitted via too small a tip/tooth overlap. Even if the slider (16) is left with the plastic spring wings (30) strained i.e. cammed towards but not beyond the centre position by a tooth (4), any stress relaxation of the spring wings occurring with time, although reducing the snap of the over-centre action of the slider in one direction, will not prevent the slider operating as in FIG. 1 since the operation is dependent upon the teeth (4) and not the spring bias.
FIG. 3 shows an alternative embodiment of shaft and drive elements in which the drive elements (12,14) are in the form of a pawl (34) which is linked to the shaft (10) by flexible links (36) allowing radial movement of the pawl (34) as indicated by the arrows. The pawl (34) will reciprocate in a similar manner to the slider (16) of FIG. 1 by the cam surfaces (22,24) acting on the teeth (4) of the annular member (not shown in FIG. 3).
A steel spring may be mounted between the pawl (34) and the shaft (10) so as to provide a snap action between two bistable positions, thus acting in a similar fashion to the embodiment of FIG. 2. Alternatively, an intrinsically bistable all moulded shaft/pawl could be produced, with an over-centre snap action. This arrangement has to be moulded in a cranked condition i.e. offset to one side, not central, and so it will have an uneven bias towards one of the two extreme radially positions although this should not significantly affect its function. In any event the device will function in absence of any spring biasing means.
In the embodiment shown in FIGS. 4 to 7 the drive elements are fixed to the shaft (10) in the form of radially outwardly extending teeth (40) each having a driving surface (42) and a cam surface (44). The outer annular member (2) is provided with radially movable, radially inwardly projecting teeth (4) each having a driving surface (6) and a cam surface (8). The teeth (4) are integrally formed with a wedging element (46) having a wedging surface (48) capable of engaging a mating surface (50) formed within the annular member (2). The wedging elements (46) are integrally formed with the annular member and attached to the interior surface by flexible tails (52) which allow radial movement of the wedging elements (46).
FIG. 6 illustrates the driving mode. The shaft (10) is rotated clockwise causing engagement of a driving surface (42) of a tooth (40) on the shaft with a driving surface (6) of a tooth (4) of the annular member (2). The engagement forces the wedging element (46) to move until the wedging surface (48) abuts the mating surface (50).
The tails (52) are almost fully extended and the wedging elements (46) have moved up to their mating surfaces (50) to ensure full engagement of the driving surfaces (42,6). This allows very high torque to be transmitted because the higher the input load the harder the wedging elements are forced into engagement with the mating surfaces of the annular member. The drive is taken through the angled mating faces and not through the thin tails (52), which serve only to retain the wedges in the mechanism.
The return non-driving cycle is shown in FIG. 7 with the shaft (10) rotating anti-clockwise. The wedging elements are initially carried anti-clockwise with the cam surfaces (44) of the shaft sliding down cam surfaces (8) and bending tails (52). The cam surface (8) of a tooth (4) encourages the tooth (4) of the wedging element to ride up over the tip of the tooth (40) on the shaft and this is repeated every time a tooth (40) goes past a wedging element. Since the only resistive forces are the friction between the shaft and the wedging elements the torque required to reverse the drive is low, or conversely the torque transmitted through the drive in the reverse direction is minimal. This is an important feature as it means that the load being driven by means of the device of this invention can be designed with quite low friction without worrying about the danger of it being back-rotated during the ratchet return cycle. This is an important requirement for a tape advance mechanism in the inhaler.
A major concern with an all plastics drive in the long term are creep and stress relaxation. The worst case scenario for this type of drive illustrated in FIGS. 4 to 7 is if the wedging elements are inadvertently left parked with their teeth (4) just on the tips of the teeth (40) of the shaft causing the tails to be bent under load for long periods of time. This is unlikely to occur if the device completes a drive cycle just prior to a long period of non-use, but is statistically quite likely if the device completes all or part of a return cycle and is then left unused. In such a situation the tails (52) will inevitably stress relax, so that the contact force between the wedging elements and the shaft decays with time. In practice there is generally enough friction remaining to force the teeth (4) on the wedging elements (46) to start to engage when the shaft starts to rotate clockwise and thus to drive the wedging surfaces (48) against the mating surfaces (50). Further rotation of the shaft forces the wedging surfaces (48) into still more positive engagement with the mating surfaces (50) and the wedging elements (46) into more positive engagement with the shaft as they slide down the steep side of the driving surfaces (42). The lost motion or backlash should never be more than 360°/N where N is the number of teeth on the shaft, because the teeth of the wedging element should not be able to slip up the steep side of the saw-tooth and out of engagement.
A device of the type disclosed above with reference to FIGS. 4 to 7 was fabricated from polyacetal and tested to advance tape in an inhaler by rotating the shaft alternatively clockwise and anti-clockwise through an angle of 180°.
The target criteria were that no advance length should be below 20 mm and the minimum of tape should be wasted whilst achieving that target i.e. lowest possible mean advance length. After 3000 actuations all advance lengths were above 20 mm with a mean of 22.83 mm.
The device was then artificially aged by deliberately parking the teeth of the wedging elements on the tips of the teeth of the shaft and leaving it in a 50° C. oven for 65 hours before re-testing.
When subsequently tested, the device did not perform quite as well as before aging because the tails had taken on a "set" in the oven. This meant that every so often it was possible for a shaft tooth to slip under the teeth of the wedging elements because they were not held in sufficient contact by the tails to cause proper engagement. On these occasions short advances were noted.
As a general guide for plastics, during accelerated aging tests each 10° C. of elevated temperature corresponds to a decade increase in time (source--RAPRA). Therefore 65 hours at 50° C. mimics 65000 hours at 20° C., or approximately 71/2 years at room temperature.
Whilst this device has been shown to be robust and reproducible and is only prone to occasional failure under the extreme conditions of being parked with the teeth of the wedging elements on the tips of the teeth of the shaft for very long periods, the performance can readily be improved.
In a preferred embodiment each wedging element (46) previously described is provided with a small projection (60) (FIGS. 5 and 6). The projection (60) has a cam profile on its outer edge which interacts with a series of lobes (62) on the inner edge of an extension (64) to the shaft radially spaced and axially offset from the teeth (40).
The cam projection (60) on the wedging elements follows the lobe profile (62) on the shaft which forces the tooth of each wedging element into partial engagement with a tooth on the shaft. Wherever the return cycle stops, the teeth of the wedging element will always be in full or partial engagement when the shaft begins to rotate to transmit drive (i.e. clockwise in the sense of FIGS. 5, 6 and 7; anti-clockwise as viewed from above in FIG. 4). As the shaft rotates the lobe surface (62) pushes on the cam projection (60) and forces the driving surfaces into engagement and this action continues until the wedging element is forced against the mating surface and into full engagement as described previously.
Such a device was tested as described above after aging for 287 hours at 61° C. with the teeth of the wedging elements parked on the tips of the shaft. This corresponds to over 3 years at 41° C. and is an extremely severe test.
After several hundred actuations there were no advance lengths below 20 mm with a mean of 23.14 mm.
FIG. 8 shows a diagrammatic cross-sectional view of an inhaler having housing (70), air inlet (72), air outlet (74), elongate carrier (76), lever (78) (an advancement mechanism), outer annular member (80), shaft (82), and slider (84).
FIGS. 9 and 10 show a diagrammatic cross-sectional views of an inhaler (89) having housing (90), air inlet (92), air outlet (94), elongate carrier (96), idler wheel (98), pivotably mounted mouthpiece cover (100), outer annular member (102), shaft (104), and slider (106). In FIG. 9, pivotably mounted mouthpiece cover (100) is in a first, closed position. In FIG. 10, pivotably mounted mouthpiece cover (100) is in a second, open position. Pivotably mounted mouthpiece cover (100) is in a torque-transmitting relationship with shaft (104), so that the movement of the pivotably mounted mouthpiece cover (100) between its first and second positions causes rotation of shaft (104) over a predetermined distance and advancement of elongate carrier (96). | A device for the transmission of one-way torque comprising an outer annular member having a plurality of radially inwardly projecting teeth each comprising a driving surface and a cam surface, and a shaft concentrically mounted with respect to the outer annular member and comprising a plurality of drive elements each having a driving surface and a cam surface. Rotation of the shaft or outer annular member in its driving direction causes engagement of a driving surface of at least one drive element with a driving surface of at least one tooth thereby resulting in joint rotation of the shaft and outer annular member. Rotation of the shaft or outer annular member in its non-driving direction causes engagement of the cam surface of at least one drive element with the cam surface of at least one tooth resulting in additional relative movement, substantially radially, between the drive element and tooth, thereby preventing rotational movement being transmitted between the shaft and the outer annular member. | 5 |
BACKGROUND and FIELD OF THE INVENTION
This invention relates to an improved system to indicate the vertical distance between points, and more particularly to a system that displays the vertical distance between points by means of sensing the pressure difference atop a fluid column through circuitry employing an electronic pressure sensor or sensors.
SUMMARY OF THE INVENTION
According to one aspect of the invention, a closed top fluid filled column is set with one end in a fixed position while the other movable end, which is terminated with a membrane that exerts no force on the enclosed fluid except for that from atmospheric pressure, is placed upon any points within the range of the system or placed a fixed vertical distance from any points. Sensing the pressure difference at the fixed position end of fluid column gives a measure that is proportional to the vertical difference between points being measured. Using an electronic pressure sensor to measure pressure then enables the pressure differential to be converted to a readable display indicating the vertical distance between points, one point being a reference.
In an alternative application of the same invention, the system configuration is similar but, two fluid columns are used with the movable ends of the fluid columns being in line with, on opposite sides of, and positioned as equal distance from a movable point that is a fixed vertical distance from any point of interest, within the range of the system. In this application, the pressures at the top or closed end of the fluid columns are averaged and the resultant is again proportional to the vertical distance between points within the range of the system. One point is a reference and the relative vertical distance of other points is measured compared to it.
The specific objective of the invention is to advance the previous state of art to:
1) allow application on an excavator
2) improve accuracy
3) improve convenience of use
4) improve durability
BRIEF DESCRIPTION OF THE DRAWINGS
These and other aspects and advantages of the invention will become more apparent by reference to the following detailed description of an embodiment when considered in conjunction with the accompanying drawings, which are schematic diagrams and illustrations of a Vertical Measurement System incorporating the principles of the invention.
FIG. 1 is a basic schematic diagram of the Vertical Measurement System.
FIG. 2 is an alternative embodiment of the Vertical Measurement System also depicting a portion of an excavator or backhoe.
FIG. 3 is a schematic diagram of the electronic circuitry that converts the output voltage of the electronic pressure sensor(s) to a digital signal that drives the display module. FIG. 4 is a side view of a backhoe or excavator stick and bucket with the applicant's Vertical Measurement System embodied in FIG. 2 attached.
FIG. 5 is a side view diagram of a backhoe with the applicant's Vertical Measurement System embodied in FIG. 2 attached.
FIG. 6 is a side view of a backhoe or excavator stick and bucket with the applicant's Vertical Measurement System embodied in FIG. 1 attached.
FIG. 7 is a side view diagram of an excavator with the applicant's Vertical Measurement System embodied in FIG. 1 attached.
DETAILED DESCRIPTION
Referring to drawing FIG. #1, a Vertical Measurement System includes a direct current voltage source which may be conveniently provided by a conventional battery 10 or a regulated power supply each having positive and negative terminals. The negative terminal of the battery 10 is connected directly to ground. Further, the illustrated Measurement System includes an electronic Pressure Sensor 12 having three terminals, low voltage which is connected to system ground, high voltage which is connected to the positive terminal of the battery, and an output voltage terminal which is connected to electronic circuitry 14, detailed in drawing FIG. #3, that converts the pressure sensor output voltage to indicate a vertical measurement on the incorporated display. The electronic circuitry 14 also is connected to the battery 10 terminals. Also, the illustrated Measurement System includes a flexible, fluid 20 filled, columnar hose 16 having a metal protective wrap, also having a cross sectional area that does not significantly change when flexed or when subjected to an internal vacuum. One end of this hose is connected to the electronic pressure sensor port and the other end 18 terminated with a membrane 22 that contains the fluid 20 but exerts no force on the enclosed fluid except for atmospheric pressure. This membrane is protected by a cover 42 which is ported 46 to the atmosphere. The configuration of the cover is not critical and is best determined by the specific application.
The Vertical Measurement System generates a desired display which represents the vertical distance between any points within range of the system by having the movable end of the fluid column 18 placed upon a reference point or a fixed distance above it, then placed upon other points or a fixed distance above them. The electronic circuitry 14 converts the electronic pressure sensor output to a readable display which represents the vertical distance between any point and the reference point. The display is continuously updated with information from the electronic pressure sensor through the electronic circuitry. This is possible because it is not necessary to include a fluid value which must be opened to obtain data. The protective fluid valve used in prior art, can be eliminated because there is very little fluid movement in the system due to the relatively small fluid cavity of the electronic pressure sensor and the constant cross sectional area of the protective wire wrapped hose used to contain the fluid column. This embodiment of the Vertical Measurement System as applied to a backhoe or excavator is illustrated in FIGS. #6 and #7.
In an alternative embodiment of the invention illustrated in drawing FIGS. #2, #4 and #5, the Vertical Measurement System is applied to a backhoe 50 or excavator. In such an application the battery 10 is the conventional battery on the backhoe or excavator. Other components of the system are as previously described and shown in drawing #1 but it may be desirable to add a second electronic pressure sensor 24, hose 26, fluid 28, and membrane 30. When utilizing two electronic pressure sensors, it is also necessary to include an averaging network shown in drawing #2 by resistors of equal value 32 and 34 but not limited to such an averaging network. In this embodiment of the invention, the movable ends of the fluid columns 18 and 36 are in line with the center of the pin 38 that connects the bucket to the end of the backhoe or excavator stick 40. The ends of the fluid columns 18 and 36 are equidistant from the pin and protected by covers 42 and 48 which are ported 46 and 48 to the atmosphere. This arrangement gives a particular advantage in this preferred embodiment of the invention in that the center of the pin 38 is a fixed distance from points of interest that are to be measured. Pin 38 also requires free access during the course of operation by the backhoe or excavator operator. The design configuration illustrated in drawing FIGS. #2, #4 and #5, yields a system equivalent of having the movable end of a fluid column at the center of the pin without hampering free access to that pin.
Applied to a backhoe or excavator, the applicant's Vertical Measurement System satisfies the previously stated objectives in a unique manner.
1) The system can be utilized on a excavator illustrated in FIG. 7 by fixing the top of the fluid column(s) at a point directly above the excavator crawler swing pivot 54. As the excavator body 52 rotates over the stationary crawler frame 56, only points directly above the swing pivot 54 are a constant vertical distance from a reference point on the ground if the crawler frame is not level. Since in most instances the crawler frame is not level, the top of the flexible fluid filled column(s) must be mounted along a line passing through the excavator crawler swing pivot 54. Since this area is not readily seen by the excavator operator, a remote pressure sensing device 12 must be used atop the fluid filled column(s), remote from the system display 14. This prevents a mechanical dial indicator from being used on a excavator but the applicant's Vertical Measurement System easily addresses the condition by utilizing an electronic pressure sensor(s)12 and remote system display 14 shown in FIGS. #1 and #7. These same comments apply to the embodiment of the Vertical Measurement System shown in FIG. #2 as applied to an excavator.
2) The applicant's Vertical Measurement System improves accuracy over previous state of art by selecting a fluid to fill the flexible column that has characteristics which compliment the selected electronic pressure sensor. The low end operating range of the Vertical Measurement System (maximum depth of the movable end of the fluid filled column(s) below the fixed position closed top end) is equal to the vertical column of fluid supported by the minimum operating pressure of the selected electronic pressure sensor. The high end operating range of the Vertical Measurement System (maximum height of the movable end of the flexible column(s) above the fixed position end of the column(s)) is equal to the height of a vertical column of fluid supported by the maximum operating pressure of the electronic pressure sensor. Accuracy is improved by selecting a fluid that is dense, so as to accentuate pressure differences atop the column(s) while meeting the other necessary characteristics of the fluid (inertness, fluidity, low freezing point). Additionally a compatible electronic pressure sensor must be selected that has an operating range which yields a total system range of approximately 24 feet. Most backhoes and excavators have an excavation depth of 24 feet or less which dictates a total system range requirement of approximately 24 feet.
Absolute accuracy of the electronic pressure sensor is proportional to its full scale reading. Therefore accuracy is improved by selecting an electronic pressure sensor with an operating range as small as possible yet one that can satisfy the total system range requirement. The specific gravity of the selected fluid coupled with the operating range of the selected electronic pressure sensor therefor have a significant effect upon accuracy. Accuracy is also improved by incorporating a ratiometric design on the input to the analog to digital converter ADC1225CCJ in FIG. #3, also by using 9 bits of conversion with the analog to digital conversion of the output voltage of the electronic pressure sensor(s).
3) The system improves convenience of use in several ways:
a) The system display 14 is remote from the electronic pressure sensor(s) 12 and 24, allowing both to be located at optimum positions, the electronic pressure sensor(s) directly above the excavator crawler swing pivot 54 and the system display in easy and close visual contact with with the backhoe or excavator operator.
b) The display is alpha numeric, indicating distance in English (feet and inches) or Metric scales. The English scale is easy to comprehend since it displays feet and inches as opposed to tenths of feet.
c) Once a single calibration point is made to any reference point, such as a grade stake, the applicant's Vertical Measurement System offers the user a continuous display of the vertical position of the movable end of the flexible fluid filled column(s). As applied to a backhoe or excavator, the operator of that equipment initially calibrates the system by placing the bucket on any known reference point and adjusts R1 of FIG. 3 which is a panel mounted potentiometer to cause the display to indicate the known elevation. Note that "0 feet and 0 inches" can also be used as the reference elevation. After this initial adjustment, the display continuously indicates the vertical position of the bucket as long as the bucket angularity relative to vertical is maintained. If the backhoe or excavator is repositioned for further excavation, the initial calibration procedure is repeated but any reference point where the elevation is known can be used, including an excavated area that was previously measured with the system.
d) The applicant's system does not require a protective fluid valve because the electronic pressure sensor has a small fluid cavity compared to typical mechanical pressure gauges and because a protective wire wrapped hose is utilized to contain the fluid column, this hose having a relatively constant cross sectional area when flexed or when subjected to an internal vacuum. Unlike previous state of art designs, no valve must be opened or closed to obtain a reading. This improves convenience of use as well as accuracy by not introducing a variable that could effect fluid pressure.
4) The system inherently has improved durability over previous state of art electronic designs because the electronic pressure sensor(s) and the electronic circuitry associated with it is located in or on the body of the excavator 52 or backhoe 50, away from the rugged environment of the bucket or stick. The durability of the membrane is also improved in that essentially no fluid is displaced from the electronic pressure sensor to the membrane or vice versa. The membrane therefore has little flexing during operation.
When an embodiment of the invention is applied to a backhoe or excavator, the invention furnishes the operator of such equipment the vertical distance of the bucket above or below an established reference point. In a Vertical Measurement System constructed in accordance with this preferred embodiment of the invention illustrated in drawing FIG. #2, the following circuit components were found to yield satisfactory results:
Battery 10: 14 volts from the backhoe standard battery regulated to 5.1 volts with a National Semiconductor LM123AK voltage regulator plus filter capacitors
Pressure Sensor 12 and 24: Fuji part number EP3445 with back side silicon sensing
Electronic Circuitry 14: Intel TP87C51FA microcontroller, a Saronix 1.8432 MHz crystal oscillator, a National Semiconductor ADC1225CCJ A/D Converter, a National Semiconductor LM358A Operational Amplifier used to establish a reference voltage, a Futaba M20SDOICA Display Module, and various resistors, capacitors and switches shown in FIG. #3
Hose 16 and 26: a vinyl inner sheave with a 1/4 inch inside diameter, protected by a wire wrap layer
Fluid 20 and 28: Prestone Ethylene glycol based antifreeze coolant
Membrane 22 and 30: Davol finger cot
Resistor 32 and 34: 27000 ohm+1% 1/4 watt
Using these selected components the following total system range and accuracy can be predicted:
System range=W/D×(Rmax-Rmin)/100 ]
where: W=the vertical column height of water supported by 1 atmosphere (100 KPa)
D=specific gravity of the fluid in the system
Rmax=the maximum operating pressure point of the selected electronic pressure sensor (KPa)
Rmin=the minimum operating pressure point of the selected electronic pressure sensor (KPa)
System range=[34 ft./1.11×(100-20)/100]
System range=24 feet, 6 inches
Accuracy=[Lerror×System range]
where: Lerror=the linearity error of the electronic pressure sensor
Accuracy=24 ft. 6 in.×0.5% maximum error
Accuracy=1.5 inches maximum error
Note: Accuracy calculations are at a constant temperature.
Other factors that could negatively affect accuracy are minimized and are not significant in the applicant's Vertical Measurement System. Factors such as:
Voltage sensitivity is minimized by use of a ratiometric design as shown in FIG. 3.
Analog to digital conversion error is minimized by using 9 bits of conversion as shown in FIG. 3.
Hysteresis is minimized by eliminating trapped air in the fluid filled column. Response time is also improved by eliminating all air from the fluid filled column.
It will now be readily appreciated that the invention provides a Vertical Measurement System which is particularly, though not exclusively, applicable to backhoes or excavators. However, it is to be understood that the preferred embodiment of the invention disclosed herein is shown for illustrative purposes only and that various modifications and alterations may be made thereto without departing from the spirit and scope of the invention. | The pressure atop a fluid filled flexible column, with the top end in a fixed position, is electronically measured and the result is utilized to indicate the vertical distance between points of interest. Associated electronics plus a suitable display, indicates the vertical distance between the points. As the lower end of the flexible fluid column is moved, the display continuously indicates the vertical distance relative to a reference point. The points of interest (one being a reference point) are measured by placing the opposite end of the flexible column on those points. As applied to a backhoe or excavator, the fluid filled flexible column is adhered to the boom and stick (major moving members of the equipment) and thereby furnishes the equipment operator the vertical position of the bucket (cutting edge of the equipment) compared to an established reference. The system continuously displays the relative vertical position of the bucket without the operator having to actuate any switch or valve. The display furnishes direct information to the operator, no manual calculations are required. | 4 |
TECHNICAL FIELD
This invention relates generally to fireplaces, and, more specifically, to prefabricated fireplace enclosures.
BACKGROUND OF INVENTION
In recent years, as many as sixty percent of new homes have been built with at least one fireplace. Many new buildings incorporate one or more fireplaces as well. The advent of “direct vent” fireplaces has allowed for relatively inexpensive installation of new fireplaces in new and existing homes and structures. Traditional masonry work, on the other hand, has become prohibitively expensive and time consuming for many.
Fireplace enclosures which surround fireplaces are typically built by contractors on site with the same materials which form the exterior of the home or building, e.g. wood, composites and siding. Therefore, in addition to building a wood or composite frame, insulation, refractory lining and/or masonry work may be required before a fireplace may be installed in a fireplace enclosure. Such additional work must be performed at the construction site, with associated labor costs, and often takes days to complete.
It is estimated that more than seventy-five percent of all fireplaces installed today are factory-built and shipped to the construction site. Most fireplaces shipped are direct vent fireplaces which vent directly outside, so there is no need for a traditional chimney or masonry. In addition, they may be installed inexpensively, without the use of skilled craftsmen. “Rear vent, direct vent” fireplaces vent from the rear of the fireplace, collecting combustible air from outside and pumping the by-products of burning gases outside. “Top vent, direct vent” fireplaces vent from the top of the fireplace using the same principles. Approximately eighty percent of new direct vent fireplaces are rear vent, while twenty percent are top vent. A “B-vent” system is a top vented system that uses room air for combustion. Some direct vent systems operate more efficiently when the vent termination is above the roof line of the associated home or building.
Fireplace enclosures which project outward from an associated living or office space, for example, require some method of support. This is typically accomplished by unattractive bracing or reinforcement, expensive masonry or concrete work, or the extension of a support member into the associated living or office space, (e.g., a support member extending four feet inside to support a two-foot deep enclosure). In addition, existing fireplace enclosures often require rerouting of mechanical, electrical and/or plumbing features.
Prior art discloses prefabricated framed fireplaces (e.g., U.S. Pat. No. 6,374,822 (Lyons, et al.)) which provide a fireplace box with an attached surrounding framework of building materials which becomes a permanent part of the wall or structure to which it is attached. The prior art, however, does not provide a fireplace enclosure adapted for compact packaging or shipping in knock-down condition. Nor does it disclose a modular fireplace enclosure which is adjustable and flexible in terms of height. For example, some top vent, direct vent systems, either for cosmetic purposes or for efficiency, require a fireplace enclosure or flue which extends upward along a substantial portion of the exterior wall of the house or building in which the fireplace is installed. The present invention solves this problem by providing stackable, essentially modular side and rear panels, whereas the prior art discloses a one-piece construction of parts integrally molded together.
In addition, the prior art requires a rough opening of substantially the same size as the fireplace box, whereas the present invention, because it is secured to the exterior wall of the structure, from the outside, has no such limitation. In addition, the prior art, because it includes brackets and/or flanges which connect to the interior of the associated structure, must be installed, at least in part, from the interior of the structure. The prior art limits access from the exterior, resulting in difficulty or inconvenience in installing associated gas and/or electric lines. Among other things, the present invention diminishes or eliminates such inconvenience and diminishes or eliminates the need to reroute such items as electrical and plumbing lines and mechanical members.
There exists a need for a simple, self-supported fireplace enclosure which is prefabricated and capable of being shipped in knock-down or disassembled condition by standard methods such as UPS, FedEx and U.S. Mail; which may be assembled quickly and efficiently at the construction site without the need for skilled contractors or additional materials such as insulation, Sheetrock or bracing members; which may be assembled from the exterior of the associated structure; which may be used in conjunction with a wide variety of fireplaces available to the public; which provides for variable height by stacking to accommodate various styles of fireplaces and configurations; and/or which allows efficient access from the exterior of the associated home or building to electric and gas lines.
DISCLOSURE OF THE INVENTION
With parenthetical reference to the corresponding elements or portions of the disclosed embodiment, merely for purposes of illustration and not by way of limitation, the present invention provides an improved fireplace enclosure, which is prefabricated and configured and arranged for simple and compact packaging and delivery to the construction site. The fireplace enclosure may be installed at the construction site quickly and efficiently, without the need for additional bracing, Sheetrock or insulation, and without the need for skilled craftsmen or experienced contractors. If the home or building to which the fireplace enclosure will be attached has a rough opening to accept a fireplace, the improved fireplace enclosure may be installed in minutes with only a drill and machine screws. Because the fireplace enclosure may be installed piece by piece from the outside of the associated structure, the installer is provided with easy access to gas and electric lines.
One aspect of the invention provides a prefabricated fireplace enclosure ( 10 ) adapted for compact packaging and connection to an exterior supporting wall of a structure, having a first side panel ( 20 ) and a second side panel ( 21 ); first ( 40 ) and second ( 44 ) mounting members securable to the supporting wall for supporting the first and second side panels, respectively; a rear panel ( 22 , 23 ) and a bottom panel ( 24 ) adapted for positioning between the first and second side panels; a roof assembly ( 25 ) adapted for support by the first and second side panels; wherein each of the panels, mounting members and roof assembly are configured and arranged so as to allow for compact packaging and shipment to the construction site in a disassembled condition. In this aspect of the invention, the resulting fireplace enclosure assembled from the foregoing components forms a part of the exterior of the structure to which it is connected.
In another aspect of the invention, the fireplace enclosure includes two upper side panels ( 27 , 29 ), two upper mounting members ( 30 , 31 ) securable to the supporting wall for supporting the upper side panels, and an upper rear panel ( 28 ) positioned between the two upper side panels, wherein the upper side panels and upper rear panels are configured so as to be vertically stacked upon the corresponding side panels and rear panels beneath them ( 20 , 21 , 22 ). This aspect of the invention provides for adjustment of the height of the fireplace enclosure. In other words, consecutive side and rear panels may be stacked upon each other, for decorative or efficiency purposes, as high as the roof line of the associated home or building.
In another aspect of the invention, the upper rear panel has two vertical edge portions ( 28 A, 28 B), a first lateral channel ( 28 C) extending parallel to a first vertical edge portion ( 28 A), and a second lateral channel ( 28 D) extending parallel to a second vertical edge portion ( 28 B), wherein the first lateral channel is adapted to receive the first upper side panel, and the second lateral channel is adapted to receive the second upper side panel.
Yet another aspect of the invention provides for an upper rear insulation pocket in the upper rear panel which is defined by the exterior wall of the upper rear panel ( 28 E) and an interior surface ( 28 F) with a width shorter than the width of the exterior wall. In another aspect, the upper rear insulation pocket has two vertical edge portions which define lateral channels in the upper rear panel.
In another aspect of the invention, the rear panel ( 22 , 23 ) has two vertical edge portions ( 22 A, 22 B, 23 A, 23 B), a first lateral channel ( 22 C, 23 C) extending parallel to a first vertical edge portion ( 22 A, 23 A), and a second lateral channel ( 22 D, 23 D) extending parallel to a second vertical edge portion ( 22 B, 23 B) wherein the first lateral channel is adapted to receive the first side panel and the second lateral channel is adapted to receive the second side panel. In another aspect, the rear panel includes a rear insulation pocket defined by the exterior wall of the rear panel ( 22 E, 23 E) and an interior surface ( 22 F, 23 F) with a width shorter than the width of the exterior wall. In yet another aspect, the rear insulation pocket has two vertical edge portions which define the first and second lateral channels of the rear panel.
In another aspect of the invention, the rear panel comprises a substantially rectangular top portion ( 22 ) and a substantially rectangular bottom portion ( 23 ). In this aspect, the top portion has a height h, the bottom portion has a height substantially equal to h, and the first and second side panels have a height substantially equal to 2h.
Another aspect of the invention provides a first ( 40 ) and second ( 44 ) mounting members or brackets, wherein the first and second side panels are adapted to be mounted on the corresponding first and second mounting bracket. In another aspect, the first and second mounting brackets are substantially U-shaped.
In another aspect of the invention, the mounting members comprise a horizontal mounting portion ( 42 , 46 ), a vertical mounting portion ( 41 , 45 ) and a brace portion ( 43 , 47 ) which is positioned between the horizontal mounting portion and the vertical mounting portion, and which supports the horizontal mounting portion.
In another aspect, the roof assembly ( 25 ) of the present invention comprises a pitched top portion ( 25 A) and two vertical side portions ( 25 B, 25 C) wherein the roof assembly is configured and arranged to be positioned on top of the first and second side panels. In another aspect of the invention, the roof assembly is secured to the first and second side panels with screws (e.g. 25 D, 25 E).
Several aspects of the invention provide that adjoining or connected members and panels are secured together with screws (e.g. 48 A, 48 B, 48 C).
In another aspect of the invention, a top panel ( 26 ) is provided which may be positioned on top of the first and second side panels, and beneath the roof assembly. In another aspect of the invention, the top panel includes a top insulation pocket defined by a top surface ( 26 A) and an interior surface ( 26 B). In this and many aspects of the invention, the top, rear, bottom and side insulation pockets comprise insulation such as Styrofoam insulation.
In another aspect of the invention, the top, bottom, side and rear panels, and the roof assembly, comprise galvanized steel.
In another aspect of the invention, the first and second side panels include side insulation pockets defined by the corresponding exterior walls ( 20 A, 21 A) and interior surfaces ( 20 B, 21 B) of the respective side panels.
In another aspect of the invention, the bottom panel includes a bottom insulation pocket defined by the bottom surface ( 24 B) and the interior surface ( 24 A) of the bottom panel. In another aspect of the invention, the first and second side panels are adapted to snap into, or interlock with, the lateral channels in the rear panel.
In another aspect of the invention, each of the top, bottom, rear and side panels, and the roof assembly, are substantially rectangular.
Another aspect of the invention provides a method of assembling a prefabricated fireplace enclosure adapted for compact packaging and connection to an exterior supporting wall of a structure. In that aspect, a first side panel and a second side panel, a first mounting member securable to the supporting wall, a second mounting member securable to said supporting wall, a rear panel and a bottom panel adapted for positioning between the first side panel and said second side panel, and a roof assembly adapted for support by said first side panel and said second side panel, are provided. The mounting members are secured to the supporting wall. The first side panel is secured to the first mounting member, and the second side panel is secured to the second mounting member. In addition, the rear and bottom panels are secured between the first side panel and said second side panel, and the roof assembly is positioned on top of the first and second side panels, whereby the fireplace enclosure is assembled and forms a part of the exterior of the structure to which it is connected.
In another aspect, first and second upper side panels, first and second upper mounting members securable to said supporting wall, and an upper rear panel adapted for positioning between said first upper side panel and said second upper side panel, are provided. The first and second upper mounting members are secured to the supporting wall above the first and second mounting members, respectively. The first and second side panels are secured to the first and second upper mounting members, and the upper rear panel is positioned between the first and second upper side panels, whereby the height of the fireplace enclosure may be adjusted.
The general object of the invention is to reduce the cost of and time associated with fireplace construction and installation.
Another object of the invention is to provide a fireplace enclosure adapted for compact packaging. Another object is to provide a prefabricated fireplace enclosure which is easy and inexpensive to ship, and which may be shipped in knock-down or disassembled condition. Yet another object is to provide a prefabricated fireplace enclosure which is easy to install.
Another object is to provide a prefabricated fireplace enclosure which requires no additional insulation, Sheetrock or support.
Another object is to provide an essentially modular fireplace enclosure with a variable height to accommodate various types of fireplaces and venting methods.
Yet another object is to provide a fireplace enclosure which permits efficient access to and installation of gas and electric lines.
These and other objects and advantages will become apparent from the foregoing and ongoing written specification, the accompanying drawings and the appended claims.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of the fireplace enclosure of the present invention.
FIG. 2 is an exploded view of the fireplace enclosure of the present invention.
FIG. 3 is a front view of the fireplace enclosure of the present invention.
FIG. 4 is a side view of the fireplace enclosure of the present invention.
FIG. 5 is a perspective view of the fireplace enclosure of the present invention depicted with attached siding, roofing and vent cap.
FIG. 6 is a perspective view of the fireplace enclosure of the present invention depicted with upper side and rear panels.
FIG. 7 is an exploded view of the fireplace enclosure of the present invention depicted with upper side and rear panels.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
At the outset, it should be clearly understood that like reference numerals are intended to identify the same structural elements, parts, portions or surfaces consistently throughout the several drawing figures, as such elements, parts, portions or surfaces may be further described or explained by the entire written specifications, of which this detailed description is an integral part. Unless otherwise indicated, the drawings are intended to be read together with the specification, and are to be considered a portion of the entire written description of this invention. As used in the following description, the terms “horizontal”, “vertical”, “left”, “right”, “up” and “down”, as well as adjectival and adverbial derivatives thereof (e.g., “horizontally”, “rightwardly”, “upwardly”, “radially”, etc.), simply refer to the orientation of the illustrated structure as the particular drawing figure faces the reader. Similarly, the terms “inwardly,” “outwardly” and “radially” generally refer to the orientation of a surface relative to its axis of elongation, or axis of rotation, as appropriate.
Referring now to the drawings, FIG. 1 illustrates a preferred embodiment of the invention in perspective view. This embodiment of the fireplace enclosure 10 is attached to the exterior or supporting wall 50 of a home or building and the corresponding framing 51 of the home or building. The embodiment includes a first side panel 20 and a second side panel 21 , a substantially rectangular top portion of the rear panel 22 and a substantially rectangular bottom portion of the rear panel 23 , and a roof assembly 25 .
FIG. 2 provides additional detail not depicted in FIG. 1 . In particular, the embodiment includes a first mounting member 40 and a second mounting member 44 , both securable to the exterior or supporting wall 50 for supporting the first side panel 20 and second side panel 21 , respectively. The first mounting member includes a vertical, U-shaped portion 41 securable to the exterior wall of the home with screws 48 A, 48 B, and a horizontal, U-shaped portion 42 supported by a brace 43 for supporting the first side panel 20 . Similarly, the second mounting member includes a vertical portion 45 , a horizontal portion 46 supported by a brace 47 , for supporting the second side panel 21 .
In this embodiment, the first side panel includes an insulation pocket defined by the exterior wall of the panel 20 A and the interior surface of the panel 20 B. Similarly, the second side panel includes an insulation pocket defined by its exterior wall 21 A and interior surface 21 B. The top portion of the rear panel 22 is defined by two vertical edges 22 A, 22 B, an exterior wall 22 E and an interior surface 22 F, which define first and second vertical channels 22 C, 22 D. Similarly, the bottom portion of the rear panel 23 is defined by two vertical edges 23 A, 23 B, an exterior wall 23 E and an interior surface 23 F, which define first and second vertical channels 23 C, 23 D. In this embodiment, the top and bottom portions of the rear panel are secured to the first and second side panels 20 , 21 with screws. In addition, the bottom panel, which is secured to the first and second side panels with screws, includes an insulation pocket defined by the interior surface 24 A and a bottom surface 24 B.
The roof assembly 25 includes a top pitched portion 25 A and two vertical side portions 25 B, 25 C. The roof assembly 25 is securable to the exterior surface of the home or building 51 with screws 25 D, 25 E, and rests upon the side panels 20 , 21 and top portion of the rear panel 22 , to which it is secured with screws.
In addition, this embodiment includes a top panel 26 having an insulation pocket defined by a top surface 26 A and a bottom surface 26 B. The top panel is also secured to the first side panel 20 and second side panel 21 with screws.
The U-shaped channels on the side of the first side panel and second side panel which face the mounting brackets 40 , 44 are configured such that the respective channels fit over or snap on the corresponding U-shaped horizontal portion 41 , 45 of the corresponding mounting bracket or member. The channels in the rear panels 22 C, 22 D, 23 C, 23 D snap on or fit over the corresponding sides of the first side panel 20 and second side panel 21 , and may be mounted or attached with screws.
FIG. 3 is a front view of this embodiment which depicts the attachment of the fireplace enclosure to the exterior or supporting wall 50 of the home or building and the framing 51 with a number of screws, e.g. 48 A, 48 B.
FIG. 4 is a side view of the fireplace enclosure in this embodiment which shows the attachment of the fireplace enclosure to the exterior or supporting wall 50 of the home or building and framing 51 with a number of screws.
FIG. 5 is an illustration of the fireplace enclosure which includes siding 61 , a vent cap 60 and roofing 62 which may be added to the fireplace enclosure after installation of the fireplace enclosure.
FIG. 6 is an illustration of another embodiment of the invention which includes first and second top side panels 27 , 29 and a top rear panel 28 which are stacked upon the corresponding first and second side panels 20 , 21 and rear panel 22 . As shown in FIG. 7 , an exploded view of FIG. 6 , this embodiment includes upper mounting members 30 , 31 which are U-shaped and stacked upon the corresponding lower mounting members 40 , 44 . The upper rear panel 28 includes two vertical edge portions 28 A, 28 B, an exterior wall or surface 28 E and an interior surface 28 F, which define vertical channels 28 C, 28 D, which vertical channels snap on or fit around the corresponding upper side panels 27 , 29 . The upper rear panel may be secured or affixed or attached to the corresponding upper side panels with screws. The described surfaces of the upper rear panel define an insulation pocket which may include Styrofoam insulation, which each of the previously described insulation pockets may include. In addition, the upper side panels 27 , 29 include insulation pockets defined in the same manner as the insulation pockets in the first side panel and second side panel.
Modifications
The present invention contemplates that many changes and modifications may be made. For example, other means may be used to secure the side panels to the mounting members, and to secure the mounting members to the supporting wall. The various panels and mounting members may also be manufactured from composite materials or plastics, for example.
Therefore, while the presently-preferred form of the improved fireplace enclosure has been shown and described, and several modifications and changes thereof discussed, persons skilled in this art will readily appreciate the various additional changes and modifications that may be made without departing from the spirit of the invention, as defined and differentiated by the following claims. | A prefabricated fireplace enclosure ( 10 ) configured and arranged for compact packaging which comprises first and second side panels ( 20, 21 ), first and second mounting members ( 40, 44 ) securable to the exterior wall of a building, a rear panel ( 22, 23 ) and a bottom panel ( 24 ) adapted for positioning between the first and second side panels, and a roof assembly ( 25 ) adapted for support by the first and second side panels, wherein each of the panels, mounting members and roof assembly are configured and arranged so as to allow for compact packaging and shipment to the construction site in a disassembled condition. | 5 |
CROSS-REFERENCE TO RELATED APPLICATION
This application is a Divisional of U.S. Patent Application Ser. No. 13/916,744, filed on Jun. 13, 2013, which claims priority under 35 U.S.C. §119 from Japanese Patent Application No. 2012-134319 filed Jun. 14, 2012. The entire contents of both applications are incorporated herein by reference.
BACKGROUND OF THE INVENTION
Field of the Invention
The present invention relates to a technique for detecting anomalies in vehicles, industrial machinery, and the like.
Description of the Related Art
Because an accident occurring in industrial machinery at a railway or plant has significant social consequences, it is very important to detect any anomaly that can occur before an accident occurs.
In order to ensure safety, sensors have been installed in vehicles and industrial machinery at various locations to monitor operations, and the measurement data obtained from these sensors has been analyzed by computers to detect anomalies.
For example, the temperature at major locations in a vehicle can be used to detect anomalies. The temperature can be measured using a laser measuring device installed near the path of a vehicle. In this way, early anomaly detection can be performed based on the measured data.
Here, knowledge related to devices used to detect anomalies is incorporated into the computers performing the analysis.
However, anomaly detection in our knowledge base has not yet reached the point of being sufficiently reliable. At this point, the reliability of anomaly detection is being increased by using anomaly patterns detected in the past and reducing the possibility of overlooking cases similar to those in the past. The related technologies described in the following literature are known.
Laid-open Patent Publication No. 7-280603 describes the use of samples in an anomaly detecting method for machinery.
International Patent Publication No. WO2008/114863 describes the calculation of the degree of similarity between patterns of change in objects observed using diagnostic equipment.
Laid-open Patent Publication No. 2008-58191 describes the calculation of the degree of similarity between standard parameter values as confidence factors in a diagnostic method for rotating machinery.
Laid-open Patent Publication No. 2009-76056 describes the use of anomaly frequency measurements in a method used to identify anomalous values.
Laid-open Patent Publication No. 2010-78467 describes a method in which a correlation coefficient matrix is created with time-series data for testing purposes and normal time-series data for reference purposes, a sparse accuracy matrix is created in which each correlation coefficient matrix is an inverse matrix, and a localized probability distribution is created for the time-series data for testing purposes and the normal time-series data for reference purposes, preferably using the accuracy matrix in a multivariate Gaussian model.
X. Zhu, Z. Ghahramani, “Semi-Supervised Learning Using Gaussian Fields and Harmonic Functions” in Proceedings of the ICML, 2003 describes semi-supervised learning based on a Gaussian random field model, and discloses labeled data and unlabeled data represented as vertices in a weighted graph.
A. B. Goldberg, X. Zhu, and S. Wright, “Dissimilarity in Graph-Based Semi-Supervised Classification” in AISTATS, 2007 describes a semi-supervised classification algorithm in which learning occurs based on the degree of similarity and dissimilarity between labeled data and unlabeled data.
SUMMARY OF THE INVENTION
Various techniques applicable to anomaly detection have been described, including those with semi-supervised algorithms, but none have suggested the use of anomaly patterns detected in the past. In other words, the effective utilization of anomaly patterns detected in the past requires arbitrary preprocessing in prior art techniques, but this does not sufficiently increase the reliability of anomaly detection.
Therefore, it is an object of the present invention to provide an analytical technique introducing existing label information into an anomaly detection model.
It is another object of the present invention to provide an anomaly detection technique able to effectively utilize label information in data including a mix of both labeled samples and unlabeled samples.
The present invention is intended to solve these problems. The effective utilization of label information is based on the idea of introducing the degree of similarity between samples. This assumes, for example, that there is a degree of similarity between normally labeled samples and no similarity to abnormally labeled samples.
Also, it is assumed that an unlabeled sample has greater a degree of similarity to a normal sample than to an anomalous sample when it has been determined from past experience that a failure is unlikely to occur, and that an unlabeled sample has an equal degree of similarity to a normal sample and to an anomalous sample when there is no previous information.
Each normalized sample is expressed by a multi-dimensional vector in which each element is a sensor value. The present invention also assumes that each sensor value is generated by the linear sum of a latent variable and a coefficient vector specific to each sensor. However, the magnitude of observation noise is formulated to vary according to the label information for the sensor values. The observation noise is set so that normally labeled≦unlabeled≦anomalously labeled.
Next, a graph Laplacian is created based on the degree of similarity between samples, the graph Laplacian is used to determine the optimal linear transformation matrix according to the gradient method or the like.
When the optimal linear transformation matrix has been obtained, an anomaly score is calculated for each sensor in the test samples according to the technique described in the Patent Application No. 2011-206087 filed by the present applicant.
The present invention is able to reduce the arbitrariness of criteria for anomaly detection and increase the reliability of anomaly detection by incorporating samples of anomaly patterns and normal patterns detected in the past into an anomaly detection model.
BRIEF DESCRIPTION OF DRAWINGS
FIG. 1 is a block diagram showing an example of a computer hardware configuration used to embody the present invention.
FIG. 2 is a block diagram showing a function configuration used to embody the present invention.
FIG. 3 is a flowchart of the process for calculating model parameters for anomaly detection according to the present invention.
FIG. 4 is a flowchart of the process for calculating anomaly scores using model parameters and the like.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
The following is an explanation of an example of the present invention with reference to the drawings. The same reference numbers are used to denote the same objects in all of the drawings except where otherwise indicated. The following explanation is a single embodiment of the present invention. The present invention is by no means intended to be limited to the content explained in the example.
FIG. 1 is a block diagram of computer hardware used to realize the system configuration and processing in an example of the present invention. In FIG. 1 , a CPU 104 , main memory (RAM) 106 , a hard disk drive (HDD) 108 , a keyboard 110 , a mouse 112 , and a display 114 are connected to a system bus 102 . The CPU 104 is preferably based on 32-bit or 64-bit architecture, and can be a Pentium® 4, Core® 2 Duo or Xeon® from Intel Corporation, or an Athlon® from Advanced Micro Devices, Inc. The main memory 106 preferably has a capacity of 4 GB or more. The hard disk drive 108 preferably has a capacity of 500 GB or more in order to store a large amount of data.
While not shown in any of the drawings, the hard disk drive 108 includes a pre-installed operating system. The operating system can be any operating system compatible with the CPU 104 . Examples include Windows XP® or Windows® 7 from Microsoft Corporation, or MacOS® from Apple, Inc.
The hard disk drive 108 also contains, as explained below with reference to FIG. 2 , a main program 202 , labeled data 204 , unlabeled data 206 , a parameter group 208 , a graph Laplacian calculation routine 210 , a parameter optimization routine 212 , and an anomaly detection routine 214 . The main program 202 , graph Laplacian calculation routine 210 , parameter optimization routine 212 , and anomaly detection routine 214 can be written in any existing programming language, including Java®, C, C++, or C#.
The keyboard 110 and mouse 112 operate on the operating system or main program 202 loaded from hard disk drive 108 into main memory 106 and displayed on display 114 , and are used to enter characters.
The display 114 is preferably a liquid crystal display. Any resolution can be used, including XGA (resolution: 1024×768) or UXGA (resolution: 1600×1200). While not shown in the drawings, display 114 is used to display operating windows for entering parameters and starting programs, and to display parameter calculation results and the like.
The following is an example of a functional configuration of the processing in the present invention with reference to the block diagram in FIG. 2 .
In FIG. 2 , the main program 202 is a program with functions integrating all of the processing. This is used by the operator to set a parameter group 208 , start the graph Laplacian calculation routine 210 , parameter optimization routine 212 , and anomaly detection routine 214 , execute calculations, and display results on display 114 .
Labeled data 204 includes data detected in the past that has been found to be anomalous or normal. An anomaly label is applied to data found to be anomalous, and a normal label is applied to data found to be normal.
Unlabeled data 206 includes unlabeled data that has not been found to be either anomalous or normal. Depending on the situation, it is treated as either labeled data 204 or unlabeled data 206 .
A single unit of data (called a sample) is a D-dimensional real vector consisting of type-D sensor values. A set of sensor data can be expressed by the equation X=[X1, . . . , XN] T ∈R N×D , where N is the number of samples.
Sensor data set X is preferably data normalized based on the original sensor data set X′[X′1, . . . , X′N] T ∈R N×D . The normalization is performed based on the following equation. Here, Xn,d is the d th element of vector Xn. The same is true of X′n,d.
μ
d
=
1
N
∑
n
=
1
N
X
n
,
d
′
σ
d
=
1
N
∑
n
=
1
N
(
X
n
,
d
′
-
μ
d
)
2
X
n
,
d
=
X
n
,
d
′
-
μ
d
σ
d
Equation
1
Also, label information Y=[Y1, . . . , YN] T ∈R N×D is provided for each sensor data set X=[X1, . . . , XN] T ∈R N×D . While not shown in the drawings, this is stored along with the labeled data 204 and the unlabeled data 206 in the hard disk drive 108 .
The label information Y is defined as follows.
Y
n
,
d
=
{
0
if
normal
,
1
if
anomaly
,
NaN
if
unlabel
,
Equation
2
Here, NaN is any real number other than 0 or 1.
In the present invention, it is assumed that each sensor value Xn,d in each normalized sample Xn is expressed as follows with a latent variable Zn∈R D′ (D′≦D), coefficients for the magnitude of noise for each label, snormal, sanomaly, sunlabel, and Gaussian noise ε with a mean of 0 and a variance of 1. Here, snormal corresponds to normal, sanomaly corresponds to anomalous, and sunlabel corresponds to unlabeled. Also, D′ is usually equal to D, but D′ is set to about 100 when D is very large and the number of data units N is small.
X
n
,
d
=
{
W
d
T
Z
n
+
s
normal
ε
,
if
Y
n
,
d
=
0
W
d
T
Z
n
+
s
anomaly
ε
,
if
Y
n
,
d
=
1
W
d
T
Z
n
+
s
unlabel
ε
,
otherwise
Equation
3
Here, the setting is snormal sunlabel sanomaly. Specific examples include snormal=1, sunlabel=3, sanomaly=5 if nothing is found; snormal=1, sunlabel=2, sanomaly=5 if the unlabeled data is found to be mostly normal; and snormal=1, sunlabel=4, sanomaly=5 if the unlabeled data is found to be mostly anomalous.
The parameter group 208 includes parameters such as noise magnitudes snormal, sanomaly, sunlabel, a scale parameter λ, and the numbers of dimensions D, D′. These are stored in the hard disk drive 108 , and can be set by the user.
The parameter group 208 also includes values used to determine a similarity matrix R. The similarity matrix is a N×N square matrix, where N is the number of samples, each row and each column correspond to samples (for example, row i/column j corresponds to the degree of similarity between the i th and j th samples), an element corresponding to a normal (labeled) sample and a normal sample is positive number a, an element corresponding to a normal sample and an anomalous sample is non-positive number b, an element corresponding to a normal sample and an unlabeled sample is c, an element corresponding to an anomalous sample and an anomalous sample is d, an element corresponding to an anomalous sample and an unlabeled sample is e, and an element corresponding to an unlabeled sample and an unlabeled sample is f. Here, a, b, c, d, e, and f satisfy the relationships b≦c≦a and e≦d≦f.
Preferably, a, b and d above are set as a=1, b=0, d=0.2.
As in the case of sunlabel, the settings for c, e and f depend on what the algorithm user has discovered regarding the unlabeled data in the application data.
Namely:
c=0.5, e=0.1, f=0.5, for example, if nothing is found;
c=0.8, e=0, f=0.8, for example, if the unlabeled data is found to be mostly normal; and
c=0, e=0.1, f=0.2, for example, if the unlabeled data is found to be mostly anomalous.
The graph Laplacian calculation routine 210 creates a similarity matrix R based on the values a, b, c, d, e, f set in the parameter group 208 , and then calculates a graph Laplacian L from the resulting similarity matrix R in the following way.
K
i
,
i
=
∑
d
=
1
N
R
i
,
d
L
=
K
-
R
Equation
4
The latent variable Z≡[Z1, . . . , ZN] T ∈ R N×D′ is realized by means of the graph Laplacian L as follows.
Pr
(
Z
)
∝
exp
{
-
λ
2
tr
(
Z
T
LZ
)
}
Equation
5
Because the probability Pr(X|W, Z, s) of X≡[X1, . . . , XN] T ∈ R N×D can be regarded as a likelihood function of parameter W≡[W1, . . . , WD] T ∈ R D×D′ and Z, parameter optimization routine 212 seeks (W*, Z*) using, for example, the gradient method so that the posterior probability is optimized. This process will be explained in greater detail below with reference to the flowchart in FIG. 3 .
The anomaly detection routine 214 calculates the anomaly score for each variable based on (W*, Z*) obtained in this manner. The anomaly detection routine 214 preferably uses the technique described in Patent Application No. 2011-206087 filed by the present applicant. The processing in the anomaly detection routine 214 will be explained in greater detail below with reference to the flowchart in FIG. 4 .
The following is an explanation of the processing used to determine the model parameters (optimal linear transformation matrix) W* and the like with reference to the flowchart in FIG. 3 .
In Step 302 of FIG. 3 , main program 202 inputs training data {X′∈RN×D,y} by retrieving labeled data 204 and unlabeled data 206 from hard disk drive 108 , normalizes the data in the manner described above, and stores the mean μd and standard deviation ad of each column d calculated when each column was normalized.
In Step 304 , main program 202 retrieves parameter D′, scale parameter λ, snormal, sunlabel, sanomaly, a, b, c, d, e, and f from the parameter group 208 or enters them into a setting screen (not shown) using keyboard 110 and mouse 112 . The scale parameter λ can be set, for example, to 0.1, and the noise magnitude and the like are determined as indicators using the cross-validation method.
In Step 306 , main program 202 calls up the graph Laplacian calculation routine 210 , and a graph Laplacian L is calculated using label information Y and a, b, c, d, e, and f. Because the graph Laplacian L calculation has already been explained with reference to FIG. 2 , further explanation has been omitted here.
In Step 308 , the main program 202 initiates W∈R D×D′ and Z∈R N×D′ . Any method can be used to perform the initialization. However, W and Z are initialized with a standard normal distribution, that is, a value of each element of W or Z is set to a realized value of a normal distribution in which the mean is 0 and the standard deviation is 1.
In Step 310 , the main program 202 sets the time variable t to 1.
In Step 312 , the main program 202 updates W in accordance with the following equation.
W:=W−α[{S· ( X−ZW T )} T Z+N ( WW T ) −1 W] Equation 6
Here, S is described as follows.
{
S
}
n
,
d
=
{
1
s
normal
if
Y
n
,
d
=
0
1
s
anomaly
if
Y
n
,
d
=
1
1
s
unlabel
otherwise
Equation
7
The operation S·(X−ZW T ) means elements n, d of matrix (X−ZW T ) are multiplied by elements n, d of S. Also, α is the learning rate and is set, for example, to 0.1. The value of a needs not be constant. It can be reduced with each iteration.
In Step 314 , the main program 202 updates Z in accordance with the following equation.
Z:=Z −α[{ S· ( X−ZW T )} W+λLZ ] Equation 8
This equation is used to perform calculations so that the parameters are updated in accordance with an update equation with a term that reduces the penalty based on the degree of similarity. This includes a term that reduces the penalty based on the degree of similarity to the latent variable of each observation. More specifically, it has been formulated so that the penalty based on the degree of similarity is the Mahalanobis distance based on the similarity matrix (or graph Laplacian). It is then calculated to converge in accordance with the gradient method.
Step 312 and Step S 314 do not have to be calculated in this order. The order can be switched.
After Step 314 , main program 202 , in Step 316 , determines the termination conditions. Here, the Frobenius norm is calculated for the matrix W′ calculated in the previous loop and the matrix W calculated in the current loop, and the termination conditions are satisfied when this is within, for example, 0.001 of a predetermined threshold value.
W
t
-
W
F
=
∑
i
=
1
D
∑
j
=
1
D
′
(
W
i
,
j
′
-
W
i
,
j
)
2
Equation
9
In Step 318 , main routine 202 increases t by “1”, and returns to Step 312 when the termination conditions have not been satisfied.
In Step 320 , main program 202 outputs the model parameters W, snormal, μ=[μ1, . . . , μD], and σ=[σ1, . . . , σD] when the termination conditions have been satisfied.
The following is an explanation of the anomaly score calculation processing performed in anomaly detection routine 214 with reference to the flowchart in FIG. 4 .
In Step 402 of FIG. 4 , main program 202 calls up anomaly detection routine 214 , and provides model parameters W, snormal, μ=[μ1, . . . , μD], σ=[σ1, . . . , σD].
In Step 404 , the anomaly detection routine 214 inputs test data {X′∈R N×D , y} by retrieving labeled data 204 and unlabeled data 206 from hard disk drive 108 , X′ in each column is normalized according the equation described above using μ and σ, and X is obtained.
In Step 406 , the anomaly detection routine 214 calculates the correlation anomaly score vector sn∈R D using the following equation.
s
n
≡
s
0
+
1
2
diag
(
Λ
X
n
X
n
T
Λ
B
-
1
)
Equation
10
Provided,
Λ
=
(
W
T
W
+
s
normal
2
I
)
-
1
B
≡
diag
2
(
Λ
)
(
s
0
)
i
≡
1
2
ln
2
π
Λ
i
,
i
Equation
11
Here, I is a unit matrix. The algorithm used to calculate the correlation anomaly score vector based on the optimal linear transformation matrix W is described in Patent Application No. 2011-206087 filed by the present applicant. It is not described in detail here.
In Step 408 , anomaly detection routine 214 outputs anomaly score vectors s1, . . . , sN based on these calculations. Each element of s1, . . . , or sN is an anomaly score for each sensor of the first, second, . . . , or N th test sample, that is, each dimension of s=each variable. A higher value indicates an anomaly.
The anomaly detection for industrial machinery at a railway or plant in the present invention was explained with reference to an example. However, the present invention is not limited to this. It can be applied to any example in which anomaly detection is performed based on a plurality of measurement parameters. | A method providing an analytical technique introducing label information into an anomaly detection model. The method includes the steps of: inputting measurement data having an anomalous or normal label and measurement data having no label as samples; determining a similarity matrix indicating the relationship between the samples based on the samples; defining a penalty based on the similarity matrix and calculating parameters in accordance with an updating equation having a term reducing the penalty; and calculating a degree of anomaly based on the calculated parameters. The present invention also provides a program and system for detecting an anomaly based on measurement data. | 6 |
BACKGROUND
[0001] 1. Technical Field
[0002] The embodiments herein generally relate to communication systems, and more particularly to the field of de-interleaving interleaved data in orthogonal frequency division multiplexing (OFDM) communication systems, such as integrated services digital broadcasting terrestrial (ISDB-T) systems.
[0003] 2. Description of the Related Art
[0004] In various communication systems, data gets distorted by channel impairments like fading, multipath prorogations, interference, Doppler Effect, etc. In case of small errors the altered bits can be corrected easily by using error correction codes, but in case of burst errors, higher numbers of data bits are altered and the transmitted data typically cannot be recovered completely. Time interleaving is performed by spreading coded symbols in time before transmission to protect data from burst errors.
[0005] OFDM based communication systems, such as ISDB-T use time interleaving to randomize modulated symbol data in the time domain in order to ensure robustness against fading interference and channel impairments. ISDB-T is used to provide many services such as data broadcasting, high definition television (HDTV), interactive TV, mobile applications, etc. ISDB-T was designed keeping in mind a mobile reception. De-interleaving requires a large memory due to the deinterleaver delay buffer and therefore, in general, the deinterleaver designs are random access memory (RAM) based. In RAM based designs, implementation of large number of memory pointers may lead to large number of counters. Such counters are generally implemented as flip-flops leading to a larger deinterleaver area and thereby resulting in greater power consumption. Hence, it would be desirable to reduce the deinterleaver area and reduce the complexity of deinterleaver design.
SUMMARY
[0006] In view of the foregoing, an embodiment herein provides an apparatus for de-interleaving interleaved data in an OFDM based ISDB-T receiver comprising of a deinterleaver memory; a OFDM symbol counter incrementing once for each OFDM symbol, wherein a practical bit width of the OFDM symbol counter is in the range of 25 bits (less conservative) to 30 bits (more conservative); a divider for calculating intra buffer offset in the deinterleaver memory for every increment of the OFDM symbol counter; a first lookup table in the deinterleaver memory for obtaining delay buffer sizes for various carriers and interleaving lengths for a given OFDM transmission layer; and a second lookup table in the deinterleaver memory for obtaining buffer base addresses for various carriers and interleaving lengths for a given OFDM transmission layer, where the bit width of the OFDM symbol counter is selected based on uninterrupted television viewing time on a particular channel.
[0007] The divider may be embodied as a combinational divider or a sequential divider. The first and second lookup tables are preferably stored in a read-only memory (ROM). Also, the first and second lookup tables may be implemented using dynamic arithmetic calculations. Preferably, the delay buffer sizes and the buffer base addresses are obtained from the first and second lookup tables for corresponding carriers and interleaving lengths for a given OFDM transmission layer.
[0008] Another embodiment, as disclosed herein, provides an apparatus for de-interleaving interleaved data in an OFDM based ISDB-T receiver comprising of a deinterleaver memory; a buffer pointer RAM adapted to store buffer pointer values, with the buffer pointer RAM using circular pointer increment logic; a first lookup table in the deinterleaver memory for obtaining delay buffer sizes for various carriers and interleaving lengths for a given OFDM transmission layer; and a second lookup table in the deinterleaver memory for obtaining buffer base addresses for various carriers and interleaving lengths for a given OFDM transmission layer, where the buffer pointer RAM size is chosen based on practical uninterrupted television viewing time on a particular channel. The buffer pointer RAM may comprise a 95×11 RAM. Moreover, the first and second lookup tables are implemented as a ROM. Preferably, the first and second lookup tables are implemented using dynamic arithmetic calculations.
[0009] Furthermore, an embodiment herein provides a method of de-interleaving interleaved data on a deinterleaver memory component in an OFDM based ISDB-T receiver using a buffer pointer random access memory (RAM) and circular pointer logic, a first lookup table to obtain delay buffer sizes for various carriers and interleaving lengths for a given OFDM transmission layer, and a second lookup table to obtain buffer base address and interleaving lengths for a given OFDM transmission layer, the method having the steps of reading a pointer value for a corresponding carrier from the buffer pointer RAM; incrementing the above read pointer value; retrieving a buffer size value for said corresponding carrier from the first lookup table; calculating intra buffer offset for a carrier by comparing said buffer size with the incremented pointer value; retrieving a buffer base address value for corresponding carrier from the second lookup table; adding calculated intra buffer offset to the buffer base address to calculate a memory address to store carrier data bits of the corresponding carrier; and storing the carrier data bits at the calculated memory address.
[0010] The RAM buffer pointer may comprise 96 stored pointer values. Also, the divider may be any of a combinational divider and a sequential divider. Moreover, the first and second lookup tables may be implemented as a ROM. Furthermore, the first and second lookup tables may be implemented using dynamic arithmetic calculations. Preferably, the delay buffer sizes and buffer base addresses are obtained for various carriers and interleaving lengths for a given OFDM transmission layer from the first and second lookup table respectively.
[0011] Also another embodiment, as disclosed herein, provides a method of de-interleaving interleaved data in a deinterleaver memory in an OFDM based ISDB-T receiver comprising of a OFDM symbol counter, a divider, a first lookup table to obtain delay buffer size and interleaving lengths for a given OFDM transmission layer, and a second lookup table to obtain buffer base address and interleaving lengths for a given OFDM transmission layer, the method performing the steps of counting received symbols by incrementing the OFDM symbol counter, where the OFDM symbol counter comprises a bit width in the range of 25 to 30 bits; retrieving a delay buffer size value for a corresponding carrier from the first lookup table; calculating intra buffer offset by dividing the OFDM symbol counter with the delay buffer size of corresponding carrier; retrieving a buffer base address for corresponding carrier from the second lookup table; combining the intra buffer offset and the buffer base address to calculate a memory address to store corresponding carrier data bits; and storing the carrier data bits at the calculated memory address. The method may further comprise implementing the first and second lookup tables as a ROM. Moreover, the method may further comprise implementing the first and second lookup tables as dynamic arithmetic calculations.
[0012] These and other aspects of the embodiments herein will be better appreciated and understood when considered in conjunction with the following description and the accompanying drawings. It should be understood, however, that the following descriptions, while indicating preferred embodiments and numerous specific details thereof, are given by way of illustration and not of limitation. Many changes and modifications may be made within the scope of the embodiments herein without departing from the spirit thereof, and the embodiments herein include all such modifications.
BRIEF DESCRIPTION OF THE DRAWINGS
[0013] The embodiments herein will be better understood from the following detailed description with reference to the drawings, in which:
[0014] FIG. 1 illustrates a time deinterleaver buffer structure;
[0015] FIG. 2 illustrates a schematic diagram of a modulo based pointer architecture in a time deinterleaver ISDB-T receiver according to an embodiment herein;
[0016] FIG. 3 illustrates a schematic diagram of a memory based pointer architecture in a time deinterleaver ISDB-T receiver according to an embodiment herein;
[0017] FIG. 4 is a flow diagram illustrating a method according to a first embodiment herein;
[0018] FIG. 5 is a flow diagram illustrating a method according to a second embodiment herein; and
[0019] FIG. 6 illustrates test data input and output timing for various embodiments herein.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
[0020] The embodiments herein and the various features and advantageous details thereof are explained more fully with reference to the non-limiting embodiments that are illustrated in the accompanying drawings and detailed in the following description. Descriptions of well-known components and processing techniques are omitted so as to not unnecessarily obscure the embodiments herein. The examples used herein are intended merely to facilitate an understanding of ways in which the embodiments herein may be practiced and to further enable those of skill in the art to practice the embodiments herein. Accordingly, the examples should not be construed as limiting the scope of the embodiments herein.
[0021] As mentioned, there remains a need for reducing the complexity of interleaver design and at the same time, reduce the interleaver area. The embodiments herein achieve this by providing systems and methods for dividing the current symbol count by the buffer size corresponding to the current input carrier index, where the resulting modulo-output representing the exact intra-buffer offset. It should be also noted that Mode 1 is used as an example, and the same idea described in the disclosure can be applicable to Mode 2 and Mode 3 for both the architectures described below. Referring now to the drawings, and more particularly to FIGS. 1 through 5 , where similar reference characters denote corresponding features consistently throughout the figures, there are shown preferred embodiments.
[0022] An ISDB-T transmitter employs time interleaving to randomize modulated OFDM symbol data in time domain in order to ensure robustness against fading interference. A convolutional interleaving scheme is used, in which every data carrier in an OFDM symbol is fed into a delay buffer of depth:
[0000] b i =I× (( i× 5)mod 96) Eq. (1)
[0000] where i is the buffer index ranging from 0 to n c −1, where n c is the number of data carriers per OFDM symbol (96, 192 or 384, depending on the system mode—respectively Mode 1, Mode 2, or Mode 3), and I is the interleaving length associated with a given OFDM transmission layer, which takes one of the following values: 0, 1, 2, 4, 8 or 16.
[0023] The operation of the convolution time deinterleaver in the ISDB-T receiver is the opposite in the sense that delay buffer depths are given by:
[0000] b* i =I× 95 I ×(( i× 5)mod 96) Eq. (2)
[0024] There are a total of 95 distinct non-zero delay buffers sizes in the deinterleaver, regardless of the system mode, since the buffer depth pattern given by Eq. (2) will repeat every 96 buffers, and also b* 19 =b* 115 =b* 211 =b* 307 =0, so the 19 th , 115 th , 211 th and 307 th data carriers in every OFDM symbol are transferred without delay.
[0025] A time deinterleaver buffer structure is illustrated in FIG. 1 , showing the first 50 buffers, with the buffer depth ranging from b* 0 =95 to b* 49 =42. As can be seen from FIG. 1 , the 19 th data carrier of the OFDM symbol is transferred without delay.
[0026] Table 1 illustrates buffer allocation in a RAM for one segment in Mode 1. It should be also noted that Mode 1 is used as an example, and the same idea described herein can be applicable to Mode 2 and Mode 3. The table shows buffer sizes and buffer base addresses in the ascending order of buffer indices. There are a total of 95 distinct buffer sizes ranging from 1 to 95, 190, 380, 760 or 1520 for I=1, 2, 4, 8 or 16, respectively.
[0000]
TABLE 1
Buffer size and Address Lookup Table
BUFFER
BUFFER SIZE
BUFFER ADDRESS
INDEX
for interleaving length I =
for interleaving length I =
i
1
2
4
8
16
1
2
4
8
16
0
95
190
380
760
1520
0
0
0
0
0
1
90
180
360
720
1440
95
190
380
760
1520
2
85
170
340
680
1360
185
370
740
1480
2960
3
80
160
320
640
1280
270
540
1080
2160
4320
4
75
150
300
600
1200
350
700
1400
2800
5600
5
70
140
280
560
1120
425
850
1700
3400
6800
6
65
130
260
520
1040
495
990
1980
3960
7920
7
60
120
240
480
960
560
1120
2240
4480
8960
8
55
110
220
440
880
620
1240
2480
4960
9920
9
50
100
200
400
800
675
1350
2700
5400
10800
10
45
90
180
360
720
725
1450
2900
5800
11600
11
40
80
160
320
640
770
1540
3080
6160
12320
12
35
70
140
280
560
810
1620
3240
6480
12960
13
30
60
120
240
480
845
1690
3380
6760
13520
14
25
50
100
200
400
875
1750
3500
7000
14000
15
20
40
80
160
320
900
1800
3600
7200
14400
16
15
30
60
120
240
920
1840
3680
7360
14720
17
10
20
40
80
160
935
1870
3740
7480
14960
18
5
10
20
40
80
945
1890
3780
7560
15120
19
0
0
0
0
0
950
1900
3800
7600
15200
20
91
182
364
728
1456
950
1900
3800
7600
15200
21
86
172
344
688
1376
1041
2082
4164
8328
16656
22
81
162
324
648
1296
1127
2254
4508
9016
18032
23
76
152
304
608
1216
1208
2416
4832
9664
19328
24
71
142
284
568
1136
1284
2568
5136
10272
20544
25
66
132
264
528
1056
1355
2710
5420
10840
21680
26
61
122
244
488
976
1421
2842
5684
11368
22736
27
56
112
224
448
896
1482
2964
5928
11856
23712
28
51
102
204
408
816
1538
3076
6152
12304
24608
29
46
92
184
368
736
1589
3178
6356
12712
25424
30
41
82
164
328
656
1635
3270
6540
13080
26160
31
36
72
144
288
576
1676
3352
6704
13408
26816
32
31
62
124
248
496
1712
3424
6848
13696
27392
33
26
52
104
208
416
1743
3486
6972
13944
27888
34
21
42
84
168
336
1769
3538
7076
14152
28304
35
16
32
64
128
256
1790
3580
7160
14320
28640
36
11
22
44
88
176
1806
3612
7224
14448
28896
37
6
12
24
48
96
1817
3634
7268
14536
29072
38
1
2
4
8
16
1823
3646
7292
14584
29168
39
92
184
368
736
1472
1824
3648
7296
14592
29184
40
87
174
348
696
1392
1916
3832
7664
15328
30656
41
82
164
328
656
1312
2003
4006
8012
16024
32048
42
77
154
308
616
1232
2085
4170
8340
16680
33360
43
72
144
288
576
1152
2162
4324
8648
17296
34592
44
67
134
268
536
1072
2234
4468
8936
17872
35744
45
62
124
248
496
992
2301
4602
9204
18408
36816
46
57
114
228
456
912
2363
4726
9452
18904
37808
47
52
104
208
416
832
2420
4840
9680
19360
38720
48
47
94
188
376
752
2472
4944
9888
19776
39552
49
42
84
168
336
672
2519
5038
10076
20152
40304
50
37
74
148
296
592
2561
5122
10244
20488
40976
51
32
64
128
256
512
2598
5196
10392
20784
41568
52
27
54
108
216
432
2630
5260
10520
21040
42080
53
22
44
88
176
352
2657
5314
10628
21256
42512
54
17
34
68
136
272
2679
5358
10716
21432
42864
55
12
24
48
96
192
2696
5392
10784
21568
43136
56
7
14
28
56
112
2708
5416
10832
21664
43328
57
2
4
8
16
32
2715
5430
10860
21720
43440
58
93
186
372
744
1488
2717
5434
10868
21736
43472
59
88
176
352
704
1408
2810
5620
11240
22480
44960
60
83
166
332
664
1328
2898
5796
11592
23184
46368
61
78
156
312
624
1248
2981
5962
11924
23848
47696
62
73
146
292
584
1168
3059
6118
12236
24472
48944
63
68
136
272
544
1088
3132
6264
12528
25056
50112
64
63
126
252
504
1008
3200
6400
12800
25600
51200
65
58
116
232
464
928
3263
6526
13052
26104
52208
66
53
106
212
424
848
3321
6642
13284
26568
53136
67
48
96
192
384
768
3374
6748
13496
26992
53984
68
43
86
172
344
688
3422
6844
13688
27376
54752
69
38
76
152
304
608
3465
6930
13860
27720
55440
70
33
66
132
264
528
3503
7006
14012
28024
56048
71
28
56
112
224
448
3536
7072
14144
28288
56576
72
23
46
92
184
368
3564
7128
14256
28512
57024
73
18
36
72
144
288
3587
7174
14348
28696
57392
74
13
26
52
104
208
3605
7210
14420
28840
57680
75
8
16
32
64
128
3618
7236
14472
28944
57888
76
3
6
12
24
48
3626
7252
14504
29008
58016
77
94
188
376
752
1504
3629
7258
14516
29032
58064
78
89
178
356
712
1424
3723
7446
14892
29784
59568
79
84
168
336
672
1344
3812
7624
15248
30496
60992
80
79
158
316
632
1264
3896
7792
15584
31168
62336
81
74
148
296
592
1184
3975
7950
15900
31800
63600
82
69
138
276
552
1104
4049
8098
16196
32392
64784
83
64
128
256
512
1024
4118
8236
16472
32944
65888
84
59
118
236
472
944
4182
8364
16728
33456
66912
85
54
108
216
432
864
4241
8482
16964
33928
67856
86
49
98
196
392
784
4295
8590
17180
34360
68720
87
44
88
176
352
704
4344
8688
17376
34752
69504
88
39
78
156
312
624
4388
8776
17552
35104
70208
89
34
68
136
272
544
4427
8854
17708
35416
70832
90
29
58
116
232
464
4461
8922
17844
35688
71376
91
24
48
96
192
384
4490
8980
17960
35920
71840
92
19
38
76
152
304
4514
9028
18056
36112
72224
93
14
28
56
112
224
4533
9066
18132
36264
72528
94
9
18
36
72
144
4547
9094
18188
36376
72752
95
4
8
16
32
64
4556
9112
18224
36448
72896
[0027] Table 2 shows the RAM size needed for one segment in Mode 1. Each buffer entry requires the number of bits equal to the data carrier soft decision width, therefore the total amount of memory required for the time deinterleaver is the combined depth of all the buffers multiplied by the data carrier bit width. This yields a very large memory size since the total combined buffer depth for one segment in Mode 1 is 72,960 entries for I=16 (see Tables 1 and 2). If the carrier bit width is assumed to be 12 bits long, the RAM memory needed will be over 10 M bits. Many times deinterleaver architectures use 95 distinct intra-buffer offset pointers (counters) implemented as flip-flops.
[0000]
TABLE 2
Total RAM Size
TOTAL RAM SIZE FOR 1 SEGMENT IN MODE 1
for interleaving length I =
1
2
4
8
16
4,560
9,120
18,240
36,480
72,960
[0028] For the simplest case of interleaving length I=1 there are 95 distinct buffer sizes ranging between 1 and 95, so for the time de-interleaving operation to be continuous (uninterrupted) the OFDM symbol counter should count up to the maximum value=LCM (least common multiple) of all natural numbers between 1 and 95, and then be reset to 0 and continue. If the larger values of the interleaving length parameter are considered, the OFDM symbol counter bit width will have to be greater than 130 bits to support the value of the above LCM, which is obviously impractical for hardware implementation.
[0029] If the worst case scenario is considered, where the shortest possible OFDM symbol length is 250 microseconds (Mode 1), the OFDM symbol counter gets incremented every 250 microseconds. If we consider realistic TV watching time, after which the user will switch to another channel or turn off the receiver, a practical value of bit width for the OFDM symbol counter can be used.
[0030] Table 3 shows the performance of 1 to 33-bit OFDM symbol counter in a receiver in terms of the maximum run time before the counter overflow occurs.
[0000]
TABLE 3
Maximum runtimes of OFDM symbol counter
OFDM
Symbol
Mode 1
Mode 2
Mode 3
Counter
0.00025
0.0005
0.001
Bits
s/symbol
s/symbol
s/symbol
1
0.001
0.001
0.002
2
0.001
0.002
0.004
3
0.002
0.004
0.008
4
0.004
0.008
0.016
5
0.008
0.016
0.032
6
0.016
0.032
0.064
7
0.032
0.064
0.128
8
0.064
0.128
0.256
9
0.128
0.256
0.512
10
0.256
0.512
1.024
11
0.512
1.024
2.048
12
1.024
2.048
4.096
13
2.048
4.096
8.192
14
4.096
8.192
16.384
15
8.192
16.384
32.768
16
16.384
32.768
65.536
17
32.768
65.536
131.072
18
65.536
131.072
262.144
19
131.072
262.144
524.288
20
262.144
524.288
1,048.576
21
524.288
1,048.576
2,097.15
22
1,048.576
2,097.152
4,194.304
23
2,097.152
4,194.304
8,388.608
0
0
0.1
24
4,194.304
8,388.608
16,777.216
0
0.1
0.2
25
8,388.608
16,777.216
33,554.432
0.1
0.2
0.4
26
16,777.216
33,554.432
67,108.864
0.2
0.4
0.8
27
33,554.432
67,108.864
134,217.728
0.4
0.8
1.6
28
67,108.864
134,217.728
268,435.456
0.8
1.6
3.1
29
134,217.72
268,435.456
536,870.912
1.6
3.1
6.2
30
268,435.46
536,870.912
1,073,741.824
3.1
6.2
12.4
31
536,870.912
1,073,741.824
2,147,483.648
6.2
12.4
24.9
32
1,073,741.824
2,147,483.648
4,294,967.296
12.4
24.9
49.7
33
2,147,483.648
4,294,967.296
8,589,934.592
seconds
24.9
49.7
99.4
days
[0031] For mode 1, the counter width of 29 bits corresponds to more than one day of TV viewing and 33 bits corresponds to about a month of TV viewing time. The OFDM symbol counter is reset to zero upon reaching the end of the current TV viewing period.
[0032] FIG. 2 shows a modulo based pointer architecture in a time deinterleaver ISDB-T receiver. The architecture is described for Mode 1 where there are 96 data carriers per OFDM symbol. However, one skilled in the art would easily realize that Mode 1 is used only as an example and is not a restriction of the various embodiments as disclosed herein. It should be also noted that Mode 1 is used as an example, and the same idea described in the disclosure can be applicable to Mode 2 and Mode 3.
[0033] There are 95 de-interleaving delay buffers and one zero delay buffer in the receiver. The architecture comprises a time deinterleaver random access memory 201 where the deinterleaver buffers are stored, a OFDM symbol counter 202 , a divider 207 , a first lookup table (LUT) 205 for obtaining delay buffer sizes of 95 delay buffers, a second lookup table (LUT) 206 for obtaining buffer base addresses of 95 delay buffers. In different embodiments, the lookup tables 205 , 206 can be implemented as a read-only memory (ROM) or using dynamic arithmetic calculations. The OFDM symbol counter 202 increments for each OFDM symbol, with bit width of OFDM symbol counter varying from 23-33 bits, while in practical applications the bit width of said OFDM symbol counter varies from 25-30 bits. The modulo divider 207 calculates the intra buffer offset for each carrier by dividing the OFDM symbol counter 202 value with the delay buffer size of the corresponding carrier obtained from the first LUT 205 . The size of the dividend is 23 to 33 bits and the divisor size is up to 11 bits. The divider may be embodied as a combinational divider or a sequential divider. The adder 208 combines the intra buffers offset and buffer base address from the second LUT 206 to calculate the memory address where the input data gets stored in the time deinterleaver RAM 201 .
[0034] FIG. 3 illustrates memory based pointer architecture in a time deinterleaver ISDB-T receiver. The architecture is described for Mode 1 where there are 96 data carriers per OFDM symbol. However, one skilled in the art would easily realize that Mode 1 is used only as an example and is not a restriction of the various embodiments as disclosed herein. It should be also noted that Mode 1 is used as an example, and the same idea described in the disclosure can be applicable to Mode 2 and Mode 3. There are 95 de-interleaving delay buffers and one zero delay buffer in the receiver. The architecture comprises a time deinterleaver RAM 201 , a buffer pointer RAM 302 , a first LUT 205 for obtaining delay buffer sizes of 95 delay buffers, a second LUT 206 for obtaining for obtaining buffer base addresses of 95 delay buffers. The buffer pointer RAM 302 stores the 95 delay buffer pointer values. The buffer pointer works with a circular pointer logic. For each data carrier the corresponding pointer value is read from the buffer pointer RAM 302 , circularly incremented using an adder 303 and written back to the buffer pointer RAM 302 . Adder 307 combines the intra buffers offset and buffer base address from the second LUT 206 to calculate the memory address where the input data gets stored in the time deinterleaver RAM 201 . In different embodiments, the lookup tables 205 , 206 can be implemented as a ROM or using dynamic arithmetic calculations.
[0035] FIG. 4 , with reference to FIGS. 1 and 2 , illustrates a method for de-interleaving interleaved data using memory based pointer architecture in accordance with the first embodiment herein. The method begins at step 410 , where for each data carrier the corresponding pointer value is read from the buffer pointer RAM 302 and incremented using adder 303 . The incremented value is stored back in the buffer pointer RAM 302 . At step 420 the delay buffer size value of the corresponding carrier is retrieved from the first LUT 205 . The incremented pointer value is compared with the retrieved buffer size value using circular increment logic to calculate the intra buffer offset at step 430 . Circular increment logic involves adding ‘1’ to the incremented pointer value and comparing the new pointer value with the retrieved buffer size value. If the new value exceeds the buffer size, the new pointer value is zeroed out. At step 440 , the buffer base address value of the corresponding carrier is retrieved from the second LUT 206 . The memory address where the input data needs to be stored is calculated by adding the intra buffer offset to the retrieved buffer base address at step 450 . Finally, at step 460 , the data bits get stored in the deinterleaver RAM 201 .
[0036] FIG. 5 , with reference to FIGS. 1 and 3 , illustrates a method for de-interleaving interleaved data using modulo based pointer architecture in accordance with the second embodiment herein. The method begins at step 510 , where OFDM symbol counter 202 counts each received symbol. At step 520 the delay buffer size value of the corresponding carrier is retrieved from the first LUT 205 . The intra buffer offset is calculated by dividing the OFDM symbol counter with retrieved delay buffer size value at step 530 using modulo divider 207 . At step 540 , the buffer base address value of the corresponding carrier is retrieved from the second LUT 206 . The memory address where the input data needs to be stored is calculated by adding the intra buffer offset to the retrieved buffer base address at step 550 . The data bits get stored in the deinterleaver RAM 201 at step 560 .
[0037] FIG. 6 illustrates the test data input timing for both the modulo based pointer architecture of FIG. 2 and the memory based pointer architecture of FIG. 3 . The incoming data carriers (DIN) are two clock cycles apart. The interleaving length is equal to 8. However, one skilled in the art would easily realize that an interleaving length of 8 is used as an example and is not a restriction of the embodiments as disclosed herein. Data is written into the deinterleaver RAM 201 every two-clock cycles apart. DOUT represents the data as taken out of the deinterleaver RAM 201 . If the incoming data is spaced many cycles apart, the size of modulo based architecture can be reduced by making the divider a sequential divider.
[0038] The architectures provided by the embodiments herein and illustrated in FIGS. 2 and 3 results in chip area savings compared with the conventional architectures. Using an example of 0.13 um standard cell technology, one scan flip-flop is roughly 40 um 2 , so for conventional design the 95×11 flip-flops alone will occupy up to 40,000 um 2 . One example of sequential divider implementation with a 25-30 bit dividend is 7,000-10,000 um 2 , plus an OFDM symbol counter of 1000-1200 um2, so the equivalent design saves about 30,000 um 2 . For a memory-based design, a 95×11 RAM is on average 5,000-7,000 um 2 , plus additional adder logic plus memory built-in self-test (BIST) overhead, so the equivalent design is under 10,000 um 2 , which also saves around 30,000 um 2 . Hence assuming that the rest of the architecture (buffer size LUT, buffer address LUT and memory address calculation logic) is the same between existing art and the proposed architectures, chip area for the intra-buffer pointer storage and calculation requires reduction.
[0039] The techniques provided by the embodiments herein may be implemented on an integrated circuit chip (not shown) and may be used in digital video broadcast systems for handheld devices, and implemented in the baseband chip sets. The chip design is created in a graphical computer programming language, and stored in a computer storage medium (such as a disk, tape, physical hard drive, or virtual hard drive such as in a storage access network). If the designer does not fabricate chips or the photolithographic masks used to fabricate chips, the designer transmits the resulting design by physical means (e.g., by providing a copy of the storage medium storing the design) or electronically (e.g., through the Internet) to such entities, directly or indirectly. The stored design is then converted into the appropriate format (e.g., GDSII) for the fabrication of photolithographic masks, which typically include multiple copies of the chip design in question that are to be formed on a wafer. The photolithographic masks are utilized to define areas of the wafer (and/or the layers thereon) to be etched or otherwise processed.
[0040] The resulting integrated circuit chips can be distributed by the fabricator in raw wafer form (that is, as a single wafer that has multiple unpackaged chips), as a bare die, or in a packaged form. In the latter case the chip is mounted in a single chip package (such as a plastic carrier, with leads that are affixed to a motherboard or other higher level carrier) or in a multichip package (such as a ceramic carrier that has either or both surface interconnections or buried interconnections). In any case the chip is then integrated with other chips, discrete circuit elements, and/or other signal processing devices as part of either (a) an intermediate product, such as a motherboard, or (b) an end product. The end product can be any product that includes integrated circuit chips, ranging from toys and other low-end applications to advanced computer products having a display, a keyboard or other input device, and a central processor.
[0041] The embodiments herein can take the form of an entirely hardware embodiment, an entirely software embodiment or an embodiment including both hardware and software elements. The embodiments that are implemented in software include but are not limited to, firmware, resident software, microcode, etc.
[0042] Furthermore, the embodiments herein can take the form of a computer program product accessible from a computer-usable or computer-readable medium providing program code for use by or in connection with a computer or any instruction execution system. For the purposes of this description, a computer-usable or computer readable medium can be any apparatus that can comprise, store, communicate, propagate, or transport the program for use by or in connection with the instruction execution system, apparatus, or device.
[0043] The medium can be an electronic, magnetic, optical, electromagnetic, infrared, or semiconductor system (or apparatus or device) or a propagation medium. Examples of a computer-readable medium include a semiconductor or solid-state memory, magnetic tape, a removable computer diskette, a random access memory (RAM), a read-only memory (ROM), a rigid magnetic disk and an optical disk. Current examples of optical disks include compact disk-read only memory (CD-ROM), compact disk-read/write (CD-R/W) and DVD.
[0044] A data processing system suitable for storing and/or executing program code will include at least one processor coupled directly or indirectly to memory elements through a system bus. The memory elements can include local memory employed during actual execution of the program code, bulk storage, and cache memories which provide temporary storage of at least some program code in order to reduce the number of times code must be retrieved from bulk storage during execution.
[0045] Input/output (I/O) devices (including but not limited to keyboards, displays, pointing devices, etc.) can be coupled to the system either directly or through intervening I/O controllers. Network adapters may also be coupled to the system to enable the data processing system to become coupled to other data processing systems or remote printers or storage devices through intervening private or public networks. Modems, cable modem and Ethernet cards are just a few of the currently available types of network adapters.
[0046] The foregoing description of the specific embodiments will so fully reveal the general nature of the embodiments herein that others can, by applying current knowledge, readily modify and/or adapt for various applications such specific embodiments without departing from the generic concept, and, therefore, such adaptations and modifications should and are intended to be comprehended within the meaning and range of equivalents of the disclosed embodiments. It is to be understood that the phraseology or terminology employed herein is for the purpose of description and not of limitation. Therefore, while the embodiments herein have been described in terms of preferred embodiments, those skilled in the art will recognize that the embodiments herein can be practiced with modification within the spirit and scope of the appended claims. | A method and apparatus for de-interleaving interleaved data in a deinterleaver memory in an Orthogonal Frequency Division Multiplexing (OFDM) based Integrated Services Digital Broadcasting Terrestrial (ISDB-T) receiver. In different embodiments, the apparatus comprises of a OFDM symbol counter along with a divider or a buffer pointer RAM with circular pointer logic, a first lookup table to obtain delay buffer size and interleaving lengths for a given OFDM transmission layer, and a second lookup table to obtain buffer base address and interleaving lengths for a given OFDM transmission layer. | 7 |
FIELD OF THE INVENTION
[0001] The present invention relates to a method for manufacturing imidazole compounds, namely sertaconazole, and salts and pseudopolymorphs thereof.
BACKGROUND OF THE INVENTION
[0002] Sertaconazole (WHO-INN) is an antifungal agent broadly used in the therapy of infections caused by fungi and yeasts in man and animals. Sertaconazole refers to 1-[2-(7-chlorobenzo[b]thiophene-3-yl-methoxy)-2-(2,4-dichloro-phenyl)ethyl]-1H-imidazole. Commonly sertaconazole is used as mononitrate salt (I).
[0003] The specification EP 151477 discloses the preparation of sertaconazole mononitrate (I) by reacting 1-(2,4-dichlorophenyl)-2-(1H-imidazol-1-yl)-ethanol (II) with sodium hydride and 3-bromomethyl-7-chlorobenzo[b]thiophene (III) in hexamethylphosphoramide (HMPA) and treating the resulting sertaconazole free base with nitric acid.
[0004] The specification CN 1358719 (CAPLUS 2003:711267) discloses the synthesis of sertaconazole mononitrate (I) by etherifying 3-bromomethyl-7-chlorobenzo[b]thiophene (III) with 1-(2,4-dichlorophenyl)-2-(1H-imidazol-1-yl)-ethanol (II) at a molar ratio of 1:1 in toluene-water (3:1, v/v) in the presence of sodium hydroxide and 50% tetrabutylammonium chloride (IV, Z=Cl) solution at 80° C. for 4 hours, extracting with ethyl ether to obtain free base of sertaconazole, salifying with nitric acid and recrystallizing in 95% ethanol. The resulting content in sertaconazole mononitrate of the thus prepared product is >98.5%.
[0005] Molecular formulas are shown in FIG. 1 / 5 .
DESCRIPTION
[0006] The present invention relates to a new chemical process for the preparation of sertaconazole mononitrate (I).
[0007] More specifically, the invention involves a process for the preparation of sertaconazole mononitrate (I) which is more efficient than those disclosed in EP 151477 and CN 1358719, and which can surprisingly provide sertaconazole mononitrate (I) of a clinical quality standard (>99.5%). In this context, sertaconazole mononitrate (I) of a clinical quality standard means material of sufficient purity for administration to humans. The particle size of the product thus obtained is 10 μm or less for at least 40% (v:v) of the whole sample and 30 μm or less for at least 95% (v:v) of the whole sample, which constitutes a suitable material to be used directly in pharmaceutical preparations.
[0008] In contrast to the specification EP 151477, the process of the present invention avoids the use of hazardous solvents such as hexamethylphosphoramide, known as chemical mutagen (The Merck Index, page 844, 13 th Edition, 2001, Merck & Co., Inc.), and ethyl ether, known as a highly flammable and explosive liquid (ibid, page 677).
[0009] Moreover, the process in the present invention is much more efficient than that disclosed in the specification CN 1358719 (CAPLUS 2003:711267), because the stoichiometric amounts of starting reactants needed to obtain 1000 g of final sertaconazole mononitrate (I) are lower than the amounts used in CN 1358719 (Table 1).
[0000]
TABLE 1
Major stoichiometric differences for obtaining 1000 g
of sertaconazole mononitrate (I)
Present
CN
Substance
invention
1358719
Reactant (II), {1-(2,4-Dichlorophenyl)-2-(1H-
2.40 mol
3.39 mol
imidazol-1-yl)-ethanol}
Reactant (III) , {3-bromomethyl-7-
2.62 mol
3.39 mol
chlorobenzo[b]thiophene}
Catalyst (IV, Z = HSO 4 , Cl)
0.121 mol
0.488 mol
{Tetrabutylammonium}
{Z = HSO 4 }
{Z = Cl}
Molar ratio IV:II
0.050
0.144
[0010] The key step in the overall process involves the dehydration of the immediate precursor, sertaconazole mononitrate monohydrate (V), to sertaconazole mononitrate (I).
[0011] Sertaconazole mononitrate monohydrate (V) has not been disclosed previously and also forms part of the invention. Sertaconazole mononitrate monohydrate (V) can also be called sertaconazole mononitrate pseudopolymorph.
[0012] In a preferred embodiment, the dehydration is carried out in a mixture of ethanol and water at 75-80° C., and slowly adding (6-8 hours) this solution over an aqueous solution of nitric acid cooled at 5-15° C., filtering, drying at 60-70° C., sieving and finally drying at 80-90° C. Sertaconazole mononitrate (I) so obtained has the sufficient purity and the proper particle size to be used directly in pharmaceutical preparations. The preparation of sertaconazole mononitrate monohydrate (V) comprises in a first step the reaction of 1-(2,4-dichlorophenyl)-2-(1H-imidazol-1-yl)-ethanol (II) with an excess of 3-bromomethyl-7-chlorobenzo[b]thiophene (III) in the presence of tetrabutylammonium hydrogen sulfate (IV, Z=HO 4 S) and sodium hydroxide in toluene at 30-45° C., followed by the addition of water, cooling the mixture to a mass temperature of 0-15° C. and filtering, washing the solid material obtained with water and toluene, and refluxing the sertaconazole free base obtained in absolute ethanol until complete dissolution, heating the mass at 60-80° C. and adding water, further cooling at 5-15° C., filtering the solid material formed and washing it with a mixture of ethanol and water, re-dissolving the pure sertaconazole free base obtained in absolute ethanol at 70-80° C., cooling the mixture at a mass temperature of 65-75° C. and thereafter adding a solution containing 60% nitric acid in water, maintaining the temperature for 10-20 minutes, keeping the pH below 2, cooling the mixture at 5-15° C. and maintaining this temperature from 30 minutes to 2 hours, followed by filtering and washing to yield sertaconazole mononitrate monohydrate (V).
[0013] In another embodiment, the molar ratio of reactant II reactant III is from 0.85 to 0.95.
[0014] In another embodiment, the molar ratio of the catalyst (IV, Z=HSO 4 ):limiting reactant (II) is from 0.025 to 0.060.
[0015] In another embodiment, the molar ratio of the catalyst (IV, Z=HSO 4 ):limiting reactant (II) is from 0.045 to 0.055.
[0016] In a more preferred embodiment, the molar ratio of the catalyst (IV, Z=HSO 4 ):limiting reactant (II) is 0.050.
[0017] Pharmaceutical compositions stand for topical preparations such as bath additives, creams, gels, ointments, cutaneous pastes, medicated plasters, cutaneous foams, shampoos, solutions for cutaneous sprays, suspensions for cutaneous sprays, powders for cutaneous sprays, cutaneous liquids, cutaneous solutions, cutaneous suspensions, cutaneous emulsions, cutaneous powders, transdermal patches, collodions, medicated nail lacquers, poultices, cutaneous sticks, cutaneous sponges, impregnated dressings, and the like; vaginal preparations such as vaginal creams, vaginal gels, vaginal ointments, vaginal foams, vaginal solutions, vaginal suspensions, vaginal emulsions, tablets for vaginal solution, pessaries, hard vaginal capsules, soft vaginal capsules, vaginal tablets, effervescent vaginal tablets, medicated vaginal tampons, vaginal delivery systems, and the like; oromucosal preparations such as gargles, concentrates for gargles, powders for gargle solutions, tablets for gargle solutions, oromucosal solutions, oromucosal suspensions, oromucosal drops, oromucosal sprays, sublingual sprays, mouth washes, tablets for mouth wash solutions, gingival solutions, oromucosal gels, oromucosal pastes, gingival gels, gingival pastes, sublingual tablets, muco-adhesive buccal tablets, buccal tablets, lozenges, compressed lozenges, pastilles, an the like; dental preparations such as dental gels, dental sticks, dental inserts, dental powders, dental solutions, dental suspensions, dental emulsions, toothpastes, and the like.
[0018] Another embodiment of the present invention is sertaconazole mononitrate (I) characterized by a particle size of 10 μm or less for at least 40% of the whole sample and 30 μm or less for at least 95% of the whole sample.
[0019] Another embodiment of the present invention is sertaconazole mononitrate monohydrate (V).
[0020] The present invention will now be described in more detail with reference to the following examples. The technical scope of the present invention is not limited to these examples.
EXAMPLE 1
Sertaconazole Mononitrate Monohydrate (V) (Sertaconazole Mononitrate Pseudopolymorph)
[0021] A 2-L flask was loaded with 308 mL of toluene, 100 g of 1-(2,4-dichlorophenyl)-2-(1H-imidazol-1-yl)-ethanol (II) (0.389 mol) and 6.67 g of tetrabutylammonium hydrogen sulfate (IV, Z=HSO 4 ) (0.0196 mol). Then, 155 g of sodium hydroxide (purity 49%; 1.905 mol) were added. The mixture was heated at 35-40° C. and stirred for 15 minutes. A solution comprising 111.11 g of 3-bromomethyl-7-chlorobenzo[b]thiophene (III) (0.425 mol) and 595 mL of toluene, maintaining the mass temperature between 37 and 40° C., was added for at least 30 minutes. After the addition, the system was maintained between 37 and 40° C. for 2.5 hours and thereafter water (635 mL) was added. The mixture was cooled to a mass temperature of 5-10° C. and the sertaconazole precipitated was filtered and washed with water and cold toluene (5-10° C.), obtaining 179.7 g of wet sertaconazole free base (161.7 g dry).
[0022] The sertaconazole free base obtained was loaded into a 2 L reactor containing 848 mL of absolute ethanol. The mixture was refluxed until complete dissolution. Then the mixture was heated at a mass temperature between 68 and 72° C., and 236 mL of water were added. The mixture was cooled at 10° C. and this temperature was maintained for 1 hour. The solid material formed was filtered and washed with a solution of 160 mL of absolute ethanol and 51 mL of water previously cooled at 10° C. Wet pure sertaconazole free base (177.9 g) was obtained (158 g dry). The obtained pure sertaconazole free base was loaded into a 2 L reactor and re-dissolved with 932 mL of absolute ethanol at 75° C. The mixture was then cooled at a mass temperature of 67-70° C. and a solution containing 53.7 g (0.512 mol) of 60% nitric acid in 193 mL of water is added. The temperature was stabilized for 15 minutes, checking that the pH was maintained below 2. The mixture was cooled at 10° C. and kept for 1 hour. The precipitated material was filtered and washed with water, providing 215.9 g of sertaconazole mononitrate monohydrate (V)(Sertaconazole mononitrate pseudopolymorph). Yield 88.7%.
Analytical Data
[0023] IR (infrared): A Magna-IR 550 Nicolet spectrometer with a database running in Omnic 2.1 software has been used. The recorded IR spectrum of sertaconazole mononitrate monohydrate (V) compared to sertaconazole mononitrate (I) is shown in FIG. 2 / 5 .
[0024] DSC (differential scanning calorimetry): A Mettler TA-8000 instrument comprising DSC-820 and TG-50 components, and a MT-5 balance provided with a database running in TAS 810 1.1 software has been used. A product sample of 1 to 5 mg was weighted in a 40 μL aluminum crucible, maintaining the following conditions:
[0000] Temperature range: 110-180° C.
Heating speed: 10° C./min
Nitrogen flow: 100 mL/min
[0025] The recorded DSC of sertaconazole mononitrate monohydrate (V) compared to sertaconazole mononitrate (I) is shown in FIG. 3 / 5 .
[0026] Microscopy: A Nikon-Eclipse E-600 unit with polarized light, provided with a Linkam THMS 600 heating plate and a Linksys database and image manager software has been used. Some product particles were suspended in mineral oil on a glass slide and the sample was examined by magnification depending on the particle size and using polarized light or not.
[0027] Sertaconazole mononitrate monohydrate (V) and sertaconazole mononitrate (I) microphotographs are shown in FIG. 4 / 5 .
[0028] X Rays Diffraction: A Siemens powder X Ray Diffraction Equipment model D-500 has been used.
[0029] The X Rays diffractograms for sertaconazole mononitrate monohydrate (V) and sertaconazole mononitrate (I) are shown in FIG. 5 / 5 . The crystal data and structure refinement for sertaconazole mononitrate monohydrate (V) are shown in Table 2.
[0000]
TABLE 2
Crystal data and structure refinement for
sertaconazole mononitrate monohydrate (V)
Empirical formula
C 20 H 15 Cl 3 N 2 OS • HNO 3 • H 2 O
Formula weight
518.78
Temperature
293(2)° K
Wavelength
0.71069 Å
Crystal system
Monoclinic
Space group
P2 1 /c
a = 16.049(2)Å
α = 90°
Unit cell dimensions
b = 8.946(7)Å
β = 102.046(7)°
c = 15.990(3)Å
γ = 90°
Volume
2245(2) Å 3
Z
4
Density (calculated)
1.535 Mg/m 3
Absorption coefficient
0.540 mm −1
Crystal size
0.1 × 0.1 × 0.2 mm
Theta range for data collection
1.30 to 30.07°
Index ranges
−3 ≦ h ≦ 16,
−12 ≦ k ≦ 12,
−22 ≦ l ≦ 21
Reflections collected
11440
Independent reflections
5861 [R(int) = 0.1748]
Refinement method
Full-matrix least-squares on F 2
Data/restraints/parameters
3246/1/336
Goodness-of-fit on F 2
0.980
Final R indices [I > 2σ(I)]
R 1 = 0.0644, WR 2 = 0.1302
R indices (all data)
R 1 = 0.3270, WR 2 = 0.2365
Extinction coefficient
0.0000(6)
Largest diff. peak and hole
0.356 and −0.429 e.Å 3
EXAMPLE 2
Sertaconazole Mononitrate (I)
[0030] Sertaconazole mononitrate monohydrate (V) (215.9 g 0.344 mol) obtained according to the previous description was dissolved in 991 mL of absolute ethanol and 150 mL of water. The mixture was heated at 75-80° C. and then added over another solution comprising 2.8 L of water and 1.7 g of 60% nitric acid which has been cooled at 10° C. for approximately 6-8 hours. Having finished the addition, the mixture was stirred for 15 minutes at 10° C. The material obtained was filtered, dried at 65° C., sieved and finally dried at 85° C., providing 162.2 g of sertaconazole mononitrate (I). Yield 93.9%. Global yield 83.3%. The particle size was 10 μm for 40% of the whole sample and 30 μm for 95% of the whole sample. MP 158-160° C. The resulting content in sertaconazole mononitrate of the prepared product was >99.5%. | The invention relates to a method for manufacturing sertaconazole mononitrate. The invention also relates tcserta-conazole mononitrate that is characterized by it: particle size and to sertaconazole mononitrate monohydrate. | 0 |
TECHNICAL FIELD
[0001] The present disclosure relates to a method and a device for removing a uterus. More particularly, the present disclosure relates to a method and a device for a novel total laparoscopic hysterectomy.
BACKGROUND
[0002] About 70% of all hysterectomies are carried out through an abdominal incision (total abdominal hysterectomies, TAH). This requires a 2 day to 4 day hospital stay, and a 6 week to 8 week recovery time. It also produces a large, permanent abdominal scar. Only 10% of the procedures are performed with a minimally invasive approach (total laparoscopic hysterectomy, TLH). TLH has major advantages over TAH: most patients are able to return home the same or next day, with a much shorter recovery period than required for other types of hysterectomies. However, the TLH procedure is surgically more difficult to perform.
[0003] The main problems in current TLH procedures are related to difficulties in reaching and visualizing parts of the uterus with the laparoscopic tools. As can be seen in FIG. 1 , the uterus is approached through small incisions on the patient's belly. In order to provide access to the desired tissue layers, the uterus needs to be moved around. A uterus mobilizer, inserted through the vagina is often used to maneuver the uterus and to create space for the laparoscopic equipment. The mobilizer does facilitate most part of dissecting the uterus, but is still limited in its ability to create sufficient room for the instruments, especially in the final phase of separating the uterus.
[0004] The location at which separation takes place is referred to as the fornix. The line of separation extends from the anterior fornix to the posterior fornix, in a 360° circular motion. The posterior side of the uterus is particularly difficult to reach. The visual feedback is poor and special caution is needed to prevent damaging surrounding structures like the bladder or intestines. These limitations lead to long procedure times. On average 15-20 minutes (up to 40 minutes) of the procedure time is spend on resolving difficulties in the actual separation of the uterus.
[0005] The disclosure is directed to a method and a device for total laparoscopic hysterectomy in which the above described problems are alleviated.
BRIEF SUMMARY
[0006] In a first aspect, a cutting device is disclosed that includes a knife assembly that can make the initial incision from the vaginal side inwards. The cutting device is suitable for use in a method for hysterectomy wherein final resection of a uterus is executed using a vaginal approach, i.e. cutting from the vaginal side inwards, instead of cutting from the abdominal side outwards of the uterus, the cutting device. However, other applications for the cutting device are feasible as well.
[0007] In a second aspect, a manipulator device is disclosed with which the uterus may be moved in a desired direction.
[0008] In a third aspect, a hysterectomy assembly is disclosed that includes a manipulator device and a cutting device and that is configured to automatically push the uterus to a direction opposite of a cutting position where the cutting device is performing a cutting operation, thereby creating as much space and visibility of the cutting position.
[0009] In a fourth aspect a hysterectomy assembly is disclosed that is configured to execute a circular cutting action for the final resection.
[0010] In a fifth aspect, a method for laparoscopic hysterectomy is disclosed wherein final resection of a uterus is executed using a vaginal approach thereby using a hysterectomy assembly according to the present disclosure.
[0011] The vaginal approach using at least one of the disclosed devices or assemblies has major benefits. Since no other tissue layers and ligaments obstruct the separation equipment, it is easier to reach the desired location. Also, improved access and ease of navigating to the fornix decreases the procedure time considerably.
[0012] This solves the problems associated with executing the resection from the abdominal cavity, i.e.:
impaired view of the operation area; impaired approach to the incision sites; and
[0015] Additional benefits may be:
improved manipulation by virtue of the new hysterectomy assembly with the integrated manipulator assembly and cutting assembly; reduced operation time; reduced risk of damaging other tissue.
[0019] The manipulator includes a manipulator element that is entered into the uterus and that may be fixated in the uterus using various fixation mechanisms. A simple fixation may be obtained by screwing the manipulator element into the uterus cavity. Once the manipulator element is in place and optionally fixated, the manipulator element may be freely rotated around a pivoting point near the entry of the uterus. The manipulation is performed manually by an operator or medical assistant during the operational procedures according to the instructions of the operating surgeon. With the hysterectomy assembly according to the invention, the manipulator element always moves the uterus away from the side of the uterus where the cutting device is active to cut the fornix.
BRIEF DESCRIPTION OF THE DRAWINGS
[0020] FIG. 1 is a cross section of the female anatomy showing the location of the uterus with its surrounding organs;
[0021] FIG. 2 is a transparent side elevation view of an example of an embodiment of a cutting assembly;
[0022] FIG. 3 is a transparent side elevation view of the cutting housing of the cutting assembly of FIG. 2 ;
[0023] FIG. 4 is a transparent side elevation view of the cutting blade cover of the cutting assembly of FIG. 2 ;
[0024] FIG. 5 is a transparent side elevation view of the cutting blade and a lever of the cutting assembly of FIG. 2 ;
[0025] FIG. 6 is a side elevation view of a distal end of the cutting blade cover actuator and a distal end of the cutting blade actuator of the cutting assembly of FIG. 2
[0026] FIG. 7 shows perspective view of the example of the cutting assembly of FIG. 2 with a transparent cutting front housing part in a condition in which the cutting blade and the cutting blade cover are accommodated in the cutting device housing;
[0027] FIG. 8 shows a similar view as FIG. 7 in which both the cutting blade and the cutting blade cover protrude distally from the cutting device housing, wherein the cutting blade protrudes distally from the cutting blade cover;
[0028] FIG. 9 shows a similar view as FIG. 7 in which both the cutting blade and the cutting blade cover protrude distally from the cutting device housing, wherein the cutting blade is completely accommodated within the cutting blade cover;
[0029] FIG. 10 shows a similar view as FIG. 7 in which the cutting blade protrudes proximally from the cutting blade cover;
[0030] FIG. 11 shows a similar view as FIG. 7 in which the cutting blade is pushed against the edge of the cutting device housing;
[0031] FIGS. 12 a and 12 b . show an example of an embodiment via which the cutting blade cover actuator and the cutting blade actuator may be operated;
[0032] FIG. 13 shows a cross section view of a distal end of an example of an embodiment of a hysterectomy assembly in a first position;
[0033] FIG. 14 shows a similar view of the example of FIG. 13 in a second position;
[0034] FIG. 15 shows a perspective view of the example in of FIG. 13 in that position;
[0035] FIG. 16 shows a perspective view of the example of FIG. 14 in that position; and
[0036] FIG. 17 a - 17 c show perspective views of the complete hysterectomy assembly in various positions;
[0037] FIGS. 18 a - 18 c show the distal parts of the hysterectomy assembly shown in FIGS. 17 a - 17 c in more detail;
[0038] FIGS. 19 a and 19 b shows a cross section view of a distal end of an example of a second embodiment of a hysterectomy assembly in a first and second position; and
[0039] FIG. 20 a - 20 e show schematically an example of an embodiment of the operation assembly for the cutting device in various positions.
DETAILED DESCRIPTION
[0040] FIG. 1 shows, as stated in the background section, a cross section of the female anatomy at the location of the uterus with its surrounding organs. FIG. 1 also shows the endoscope directed to the uterus.
[0041] FIG. 2 is a transparent side elevation view of an example of an embodiment of a cutting assembly. The reference numbers of FIG. 2 relate to the following:
1 . Cutting device housing 13 . Cutting blade cover 23 . Cutting blade 28 . Lever 31 . Cutting blade actuator; 34 . Cutting blade cover actuator;
[0048] FIG. 3 is a transparent side elevation view of the cutting housing of the cutting assembly of FIG. 2 . The reference numbers of FIG. 3 relate to the following:
1 . Cutting device housing configured to accommodate the cutting blade cover, the cutting blade, the cutting blade cover actuator and the cutting blade actuator 2 . Opening in the cutting device housing 1 to allow protrusion of the cutting blade cover 13 and the cutting blade 23 . 3 . Opening in the cutting device housing 1 to allow passage of the cutting blade cover actuator 34 . 4 . Opening in the cutting device housing 1 to allow passage of the cutting blade actuator 31 . 5 . Partition wall forming one side of the guiding groove 6 of the cutting blade cover actuator 34 and one side of the guiding groove 7 for the cutting blade actuator 31 . 6 . Guiding groove for cutting blade cover actuator 34 . 7 . Guiding groove for cutting blade actuator 31 . 8 . Rounded corner serving as a hinge for the cutting blade cover 13 . 9 , 10 . Sides of the space in the cutting device housing 1 that serve as a guiding groove for the cutting blade cover 13 . 11 . Area of the cutting device housing 1 toward which the cutting blade 23 cuts. 12 . Guiding groove for the notch 18 of the cutting blade cover 13 .
[0060] FIG. 4 is a transparent side elevation view of the cutting blade cover 13 of the cutting assembly of FIG. 2 . The reference numbers of FIG. 4 relate to the following:
13 . Cutting blade cover having a front part and a rear part between which the cutting blade 23 is accommodated 14 . Rounded outer edge of the cutting blade cover 13 . 15 . Rounded inner edge of the cutting blade cover 13 . 16 . Elevated bulges reducing friction of the sliding movement of the cutting blade cover 13 within the cutting device housing 1 . Additionally, the elevated bulges create a distance between the cutting blade cover 13 and the cutting device housing 1 to form a space in which the cutting blade actuator 31 and cutting blade cover actuator 34 extend. 17 . Elevated ridge reducing friction of the sliding movement of the cutting blade cover 13 within the cutting device housing 1 . 18 . Notch that moves within guiding groove 12 of the cutting device housing 1 and together with rounded outer and inner edge 14 , 15 limits the freedom of movement of the cutting blade cover 13 within the cutting device housing 1 to one path and related angle. Notch 18 is also engaged by the cutting blade cover actuator 34 . 19 . Guiding groove in a front part of the cutting blade cover 13 for co-operation with a notch 30 of the lever 28 of the cutting blade 23 . 20 . Guiding groove in the rear part of the cutting blade cover 13 for co-operation with one of the notches 27 of the blade 23 . 21 . Opening in the cutting blade cover 13 allowing protrusion of the cutting blade 23 for the stabbing function 22 . Opening in the cutting blade cover 13 allowing for protrusion of the cutting blade 23 for the cutting function
[0071] FIG. 5 is a transparent side elevation view of the cutting blade 23 and a lever 28 of the cutting assembly of FIG. 2 . The reference numbers of FIG. 5 relate to the following:
23 . Cutting blade. 24 . Sharp edge of the cutting blade for the stabbing function. 25 . Sharp edge of the cutting blade 23 for the cutting function. 26 . Notch that fits in the lever 28 . 27 . Notch that moves within the guiding groove 20 for the cutting blade 23 . 28 . Lever. 29 . Hole in the lever 28 for the notch 26 of the cutting blade 23 30 . Notch that moves in the guiding groove 20 of the cutting blade cover 13 and is engaged by the cutting blade actuator 31 .
[0080] FIG. 6 is a side elevation view of a distal end of the cutting blade cover actuator 34 and a distal end of the cutting blade actuator 31 of the cutting assembly of FIG. 2 . The reference numbers of FIG. 6 relate to the following:
31 . Cutting blade actuator. 32 . Slot for notch of the lever 28 . 33 . Handle of the cutting blade actuator 31 that slides in the blade handle guiding groove 7 of the cutting device housing 1 . 34 . Cutting blade cover actuator. 35 . Slot for the notch 18 of the cutting blade cover 13 . 36 . Handle of the cutting blade cover actuator 34 that slides in the cover handle guiding groove 6 of the cutting device housing 1 .
[0087] FIG. 7 shows perspective view of the example of the cutting assembly of FIG. 2 with a transparent cutting front housing part in a condition in which the cutting blade 23 and the cutting blade cover 13 are accommodated in the cutting device housing 1 ;
[0088] In FIG. 8 the cutting blade 23 and the cutting blade cover 13 both protrude distally from the cutting device housing 1 and wherein the cutting blade 23 protrudes distally from the cutting blade cover 13 .
[0089] In FIG. 9 the cutting blade 23 and the cutting blade cover 13 both protrude distally from the cutting device housing 1 and cutting blade 23 is fully accommodated within the cutting blade cover 13 .
[0090] In FIG. 10 the cutting blade 23 protrudes proximally from the cutting blade cover 13 .
[0091] In FIG. 11 the cutting blade 23 is pushed against the edge 11 of the cutting housing 1 .
[0092] The cutting assembly includes a stabbing and cutting blade 23 within a protecting cutting blade cover 13 . The cutting blade 23 is moveable within the cutting blade cover 13 . The cutting blade cover 13 is moveably positioned in a cutting device housing 1 or 43 (see FIGS. 2 , 13 , 14 ). The possible movement of the cutting blade 23 with respect to the cutting blade cover 13 is uniquely determined by two notches 26 and 27 on the blade 23 . Notch 27 engages in a guiding groove 20 in the cover 13 and notch 26 engages in a hole 29 in a lever 28 . Lever 28 in turn engages in a guiding groove 19 in the cutting blade cover 13 thus limiting the movement of notch 27 to the middle of the guiding groove 19 in the cutting blade cover 13 . The guiding grooves 19 and 20 are located on respectively the front and the rear part of the cutting blade cover 13 thus allowing trajectories of the guiding grooves 19 , 20 to overlap. The possible movement of the cutting blade 23 is thus uniquely determined by the contour or shape of the guiding grooves 19 , 20 . A cutting blade actuator 31 is engaged to the notch 30 on the lever 28 by a slot 32 and is used to move the cutting blade 23 to different positions with respect to the cutting blade cover 13 within the range of positions that is determined by the guiding grooves. A guiding groove 7 in the cutting device housing 1 prevents rotation of the cutting blade actuator 31 with respect to the cutting device housing 1 and limits the movement of the cutting blade actuator 31 to the distal and proximal direction.
[0093] The lever 28 only functions to offset the engagement of the attachment of the cutting blade actuator 31 to a more proximal position to prevent this engagement position to protrude from the cutting device housing 1 when performing the stabbing and cutting actions.
[0094] The movement of the cutting blade cover 13 within the cutting device housing 1 is limited by the shape of the cover 13 and the shape of the inner space of the cutting device housing 1 .
[0095] The rounded outer side 14 of the cutting blade cover 13 is concentric with the rounded inner side 15 of the cutting blade cover 13 . The width of the inner space of the cutting device housing 1 is equal to the sum of the radii of the rounded inner side 15 and the rounded outer side 14 of the cutting blade cover 13 . This configuration laterally limits the movement of the cutting blade cover 13 relative to the cutting device housing 1 . The movement of the cutting blade cover 13 in the distal and proximal direction within the cutting device housing 1 as well as the rotation of the cutting blade cover 13 within the cutting device housing 1 is determined by a notch 18 on the cutting blade cover 13 which can slide within a guiding groove 12 in the cutting device housing 1 . Any specific position of notch 18 within the guiding groove 12 determines the position in the distal and proximal direction as well as the angle of the cutting blade cover 13 with respect to the cutting device housing 1 . A cutting blade cover actuator 34 is in engagement with notch 18 via a slot 35 . By moving the handle 36 of the cutting blade cover actuator 34 , the cutting blade cover 13 is moved to different positions with respect to the cutting device housing 1 within the range of positions that is determined by the guiding groove 12 .
[0096] A guiding groove 6 in the cutting device housing 1 prevents rotation of the cutting blade cover actuator 34 with respect to the cutting device housing 1 and limits the movement of the cutting blade cover actuator 34 to the a distal and proximal direction relative to the cutting device housing 1 .
[0097] The cutting blade cover 13 of the present example incorporates three bulges 16 and an elevated ridge 17 to allow smooth movement within the cutting device housing and to create space for the actuators 31 and 34 , thus compensating for any notches sticking outward of the surface of the cover and also reducing the friction of the cutting blade cover 13 within the cutting device housing 1 .
[0098] The shapes of the guiding groove 12 and the slots 32 and 35 are chosen such that if the handles 33 and 36 are each moved with the same distance, the position of the cutting blade 23 does not change with respect to the cutting blade cover 13 .
[0099] The combination of the position and contour of the guiding grooves 19 and 20 allow the cutting blade 23 to be positioned in a safe position within the cutting blade cover 13 , protrude outwards through opening 21 of the cutting blade cover 13 for a stabbing position or to move in a cutting action through opening 22 in the cutting blade cover 13 . A distal tip of the rear and the front part of the cutting blade cover 13 may be connected to each other to provide structural strength to the cutting blade cover 13 . This interconnection that may be formed by a spot weld, forms an obstacle for a simple movement of the cutting blade 23 relative to the cutting blade cover 13 . The notches and guiding grooves as discussed above and shown in the figures may provide a path of movement of the cutting blade 23 relative to the cutting blade cover 13 so that the distal end of the cutting blade 23 is steered around the spot weld.
[0100] Normal operation of the system: The cutting blade 23 is set in the stabbing position protruding outward of opening 21 by moving the handle 33 of the cutting blade actuator 31 in the most distal position with respect to the handle 36 of the cutting blade cover actuator 34 . With the blade 23 in the stabbing position the handles of the cutting blade actuator 31 and the cutting blade cover actuator 34 are simultaneously moved in the distal direction thus pushing the cutting blade cover 13 with the protruding cutting blade 23 outward and slightly rotating until the cutting blade cover 13 has reached its maximum position. The protruding cutting blade 23 will make the initial cut through the tissue and the cutting blade cover 13 will dilate the initial cut by its wedge shape. When the cutting blade cover 13 has reached its maximum position, the cutting blade 23 will be pulled back to its safe position by moving the handle of the cutting blade actuator 31 with respect to the handle of the cutting blade cover actuator 34 . The cutting device assembly is now ready to make the first cut by moving the handle of the cutting blade actuator 31 further proximally with respect to the handle of the cutting blade cover actuator 34 until the blade 23 has completed the full movement toward and onto the area 11 of the cutting device housing 1 that limits the movement of the cutting blade 23 . The surgeon may now choose to rotate the whole system and make a second cutting action by moving the cutting blade 23 upwards or to first move the cutting blade 23 upwards into the safe position before rotating the system and repeating the initial cutting movement. This procedure is repeated until the full 360° has been cut and the uterus is fully resected.
[0101] FIG. 12 shows an example of an embodiment via which the cutting blade cover actuator and the cutting blade actuator may be operated. Rotatable knob 100 may be positioned in a stabbing position in which the cutting blade 23 protrudes distally from the cutting blade cover 13 as shown in FIG. 8 . Rotatable knob 100 may be positioned in a cutting position in which movement of handle 102 , relative to handle 104 is possible as indicated with arrow 106 . The rotatable knob 100 may also be positioned in a safe position in which the cutting blade is positioned entirely within the cutting blade cover 13 . The cutting blade cover may be moved in and out of the cutting device housing 1 by movement of inner tube 108 relative to outer tube 110 as indicated by arrow 112 . The cutting device housing 1 may be connected directly or indirectly to the outer tube 110 . The rotatable knob 100 may also be embodied as a shiftable knob 100 as shown in the exemplary embodiment of FIGS. 20 a - 20 e.
[0102] FIG. 13 shows a cross section view of a distal end of an example of an embodiment of a hystorectomy assembly in a first position and FIG. 14 shows a similar view of the example of FIG. 13 in a second position. FIG. 15 shows a perspective view of the example in of FIG. 13 in that position and FIG. 16 shows a perspective view of the example of FIG. 14 in that position.
[0103] The reference numbers of FIG. 13-16 relate to the following:
37 . Mobilizer assembly. 38 . Outer tube. 39 . Inner tube. 40 . Mobilizer element frame. 41 . Mobilizer element. The mobilizer element is also named manipulator element in this application. 42 . Cutting device holder. 43 . Blade cutting device housing or cutting device housing. 44 . Gear wheel connection between outer tube and mobilizer element frame, consisting of gear wheel 44 a and gear wheel 44 b 44 a . Gear wheel on the outer tube 38 44 b . Gear wheel on the mobiliser element frame 40 45 . Gear wheel connection between inner tube and blade holder, consisting of gear wheel 45 a and gear wheel 45 b 45 a . Gear wheel on the inner tube 39 45 b . Gear wheel on the cutting device holder 42
[0117] When rotating the system, the mobiliser element 41 is automatically moved in a direction which is optimal for the cutting procedure and allows optimal vision for the surgeon.
[0118] FIG. 19 a shows a cross section view of a distal end of a second embodiment of a hystorectomy assembly in a first position and FIG. 19 b shows a similar view of the example of FIG. 19 a in a second position.
[0119] The reference numbers of FIGS. 19 a and 19 b relate to the following:
43 . Blade cutting device housing or cutting device housing. 137 . Mobilizer assembly. 138 . A second tube. 139 . A first tube. 141 . Mobilizer element that may include a mobilizer element frame 140 . The mobilizer element 141 is also named manipulator element in this application. 142 . A Cutting device holder. 143 . A gear wheel connection between first tube 139 and the cutting device holder 142 , 144 . A gear wheel connection between a third tube 145 and a rotation ring 146 . 145 . A third tube 146 . A rotation ring 147 . A gear wheel connection between the rotation ring 146 and the mobilizer element 141 or the mobilizer element frame 140 .
[0131] When rotating the first tube 139 relative to the second and third tubes 138 , 145 , the mobiliser element 141 is automatically moved in a direction which is optimal for the cutting procedure and allows optimal vision for the surgeon.
[0132] In a first embodiment, the cutting device 43 may be embodied as a cutting device 1 as described with reference to FIGS. 1-12
[0133] In an other embodiment, the cutting device 43 could be replaced by a different dissection mechanism, like thermal dissection, ultrasone dissection or any other technique or combination of techniques that can fit to this system.
[0134] Explanation of the Mobiliser System.
[0135] The system includes a handle having an inner tube 39 and an outer tube 38 which can rotate with respect to each other, but can not move in the longitudinal direction with respect to each other.
[0136] On the upper side of the inner tube a mobilizer element frame 40 is connected such that it can rotate around an axis A3 which has an angle of φ1 with respect to axis A1 of the inner tube 39 . The mobilizer element frame 40 can only rotate but it can not move in the direction of the axis of rotation with respect to the inner tube 39 . The mobilizer element frame 40 is engaged with the outer tube 38 through a gearwheel 44 or any other mechanism that ensures that the rotation of the outer tube 38 with respect to the inner tube 39 is passed on to a similar rotation of the mobilizer element frame 40 . The mobilizer element frame 40 contains a mobilizer element 41 with an axis that has an angle of φ2 with respect to the angle of the axis of rotation of the mobilizer element frame 40 . A cutting device holder 42 is place around the mobilizer element 41 such that it can rotate around the mobilizer element 41 , but it can not move in the direction of the axis of the mobilizer element 41 with respect to the mobilizer element 41 . The cutting device holder 42 engages with the inner tube 39 through a gearwheel 45 or any other mechanism that ensures that the rotation of the inner tube 39 with respect to the mobilizer element holder 40 is passed on to a similar rotation of the cutting device holder 42 .
[0137] A cutting device housing 1 or 43 is fixedly attached to the cutting device holder 42 at a certain angle with respect to the axis of the mobilizer element 41 .
[0138] A second embodiment of the system, of which an example is shown in FIGS. 19 a and 19 b , includes a handle having an first tube 139 , a second tube 138 and a third tube 145 which can rotate with respect to each other around an first axis A1. The respective tubes can not move in the longitudinal direction with respect to each other.
[0139] On the upper side of the second tube 138 a cutting device holder 142 is connected such that it can rotate around an axis A3 which has an angle of φ1 with respect to axis A1 of the outer tube 138 . The cutting device holder 142 can only rotate but it can not move in the direction of the axis of rotation with respect to the outer tube 138 . The cutting device holder 142 is engaged with the first tube 139 through a gearwheel 143 or any other mechanism that ensures that the rotation of the inner tube 139 with respect to the outer tube 138 is passed on to a similar rotation of the cutting device holder 142 . A rotation ring 146 is connected such that it can rotate around axis A3, but it cannot move in the direction of the axis of rotation with respect to the cutting device holder 142 . The third tube 145 is engaged with the a proximal gear of rotating ring 146 through a gearwheel 144 or any other mechanism that ensures that the rotation of third tube 145 with respect to the first tube 139 is passed on to a similar rotation of the rotation ring 146 . A distal gear of the rotation ring 146 is engaged with a gear 147 that is part of the mobilizer element 141 or the mobilizer element frame 140 of the mobilizer element 141 . Any other mechanism that ensures that the rotation of the rotation ring 146 relative to the cutting device holder 142 is passed on to a similar rotation of the mobilizer element 141 or the mobilizer element frame 140 . The axis A2 of the mobilizer element 141 makes an angle of φ2 with the axis of rotation of the cutting device holder 142 . A mobilizer element 141 or the mobilizer element frame 140 is placed on the cutting device holder 142 such that it can rotate around its axis A2 on the cutting device holder 142 , but it can not move in the direction of the axis A2 relative to the cutting device holder 142 . The mobilizer element 141 or mobilizer element frame 140 engages the third tube 145 through the gearwheel 147 , the rotation ring 146 and the gearwheel 144 or any other mechanism that ensures that the rotation of the third tube 145 with respect to the first tube 139 is passed on to a similar rotation of the mobilizer element 141 .
[0140] A cutting device housing 1 or 43 is fixedly attached to the cutting device holder 142 at a certain angle with respect to the axis of the mobilizer element 141 .
[0141] Normal functioning of the system: When the outer tube 38 is held in a stable position and the inner tube 39 is rotated with respect to the outer tube 38 , the mobilizer element 41 moves in a cone shape, but the mobilizer element 41 does not rotate around its longitudinal axis with respect to the outer tube 38 because of the gear wheel engagement between the outer tube 38 and the mobilizer element frame 40 . The person operating the system can thus move the mobilizer element to any position on the cone shape by holding the outer tube 38 and rotating the inner tube 39 with respect to the outer tube 38 without the risk that the mobilizer element 41 will either dislocate from the uterus by rotating counter clockwise (and thus unscrewing from the uterus) or the risk that the mobilizer element 41 will unintentionally screw itself further into the uterus with the risk of protruding into the abdominal cavity.
[0142] When the inner tube 39 is rotated with respect to the outer tube 38 the cutting device holder 42 rotates around the mobilizer element 41 .
[0143] In this embodiment, when both φ1 and φ2 are 45°, the axis of the mobilizer element 41 moves from parallel to the axis of the outer tube 38 (FIG. 12 ) to perpendicular to the axis of the outer tube 38 ( FIG. 13 ). The parallel position corresponds to positioning the uterus in a position whereby it is stretched towards the intestines, revealing the side of the uterus towards the bladder. The 90° angle pushes the uterus to a forward lying position towards the bladder, revealing the side of the uterus towards the intestines. An indicator on the outer tube 38 can show in which position the outer tube should be held to achieve these intended angles.
[0144] In other embodiments the angles can be varied to allow for different shapes and axis of the cone movement of the mobilizer element 41 .
[0145] In the second embodiment the third tube 145 can rotate around the second tube 138 or it can be rotationally fixed to the second tube 138 . When the second tube 138 and the third tube 145 are held in a stable position and the first tube 139 is rotated with respect to the second tube 138 , the axis A2 of the mobilizer element 141 moves in a cone shape, but the mobilizer element 141 does not rotate around its longitudinal axis with respect to the second tube 138 and the third tube 145 because of the gear wheel engagement between the third tube 145 , the rotation ring 146 and the mobilizer element 141 or the mobilizer element frame 140 . The person operating the system can thus move the mobilizer element 141 to any position on the cone shape by rotationally fixing the third tube 145 to the second tube 138 , holding the third tube 145 and rotating the first tube 139 with respect to the third tube 145 without the risk that the mobilizer element 141 will either dislocate from the uterus by rotating counter clockwise (and thus unscrewing from the uterus) or the risk that the mobilizer element 141 will unintentionally screw itself further into the uterus with the risk of protruding into the abdominal cavity.
[0146] When the third tube 145 is rotationally fixed to the second tube 138 and the first tube 139 is rotated with respect to the third tube 145 the cutting device holder 142 rotates around the mobilizer element 141 .
[0147] In this embodiment, when both φ1 and φ2 are 45°, the axis A2 of the mobilizer element 141 moves from parallel to the axis A1 of the second tube 138 ( FIG. 20 a ) to perpendicular to the axis A1 of the second tube 138 ( FIG. 20 b ). The parallel position corresponds to positioning the uterus in a position whereby it is stretched towards the intestines, revealing the side of the uterus towards the bladder. The 90° angle pushes the uterus to a forward lying position towards the bladder, revealing the side of the uterus towards the intestines. An indicator on the second tube 138 can show in which position the second tube 138 should be held to achieve these intended angles.
[0148] In other embodiments the angles can be varied to allow for different shapes and axis of the cone movement of the mobilizer element 141 .
[0149] When the first tube 139 is not rotated with respect to the second tube 138 and the third tube 145 is rotated with respect to the second tube 138 , the mobiliser element 141 will rotate around its own axis A2, without changing the direction of the axis A2, and without changing the position of the cone in the cone shape. That can be done when the mobilizer element 141 has to be screwed into the uterus.
[0150] Normal operation of the system: The outer tube 38 or 138 is held in a position according to the indicator and the inner tube 39 or 139 is rotated until the axis A2 of the mobilizer element 41 or 141 is parallel to the axis A1 of the outer tube 38 or 138 . The system is then inserted into the vagina and in the first embodiment the mobilizer element 41 is screwed into the uterus by rotating the whole system, without allowing any rotation of the inner tube 39 with respect to the outer tube 38 , or by any other mechanism suited to attach the mobilising element 41 to the uterus. In the second embodiment the mobiliser element 141 is screwed into the uterus by rotating the third tube 145 with respect to the second tube 138 without allowing any rotation of the first tube 139 or the second tube 138 , The end position of the system should correspond with the optimal rotational position as revealed by the indicator. The system is now ready to be used as a manipulator, whereby the angle of the mobilizer element 41 or 141 is manipulated by rotating the inner tube 39 or the first tube 139 and holding the outer tube 38 or the second tube 138 in its optimal position as revealed by the indicator. In the second embodiment the third tube 145 should then be rotationally fixed relative to the second tube 138 , allowing a similar operation as in the first embodiment.
[0151] When the final resection has to be performed and the surgeon elects to perform the final resection with the stabbing cutting mechanism of the cutting device 1 , the cutting device housing 1 , 43 is moved to the optimal position for the initial cut using the stabbing mechanism. In order to aid the surgeon in selecting the optimal position, the top of the blade cutting device housing may contain a light source, which light can be seen from the abdominal side. The light allows the surgeon to double check that no major arteries or veins are still present in the cutting region. By rotating the inner tube 39 with respect to the outer tune 38 , the cutting device housing 43 is set in the optimal rotational position. The mobilizer element 41 automatically moves the uterus to a position whereby the tissue to be cut is stretched a little, the uterus is moved away from organs to avoid damage by the cutting action and the surgeon has optimal vision of the cutting site. The surgeon can now perform the stabbing action followed by the first cutting action. After the first cutting action the position of the blade cutting device housing 43 is rotated by rotating the inner tube 39 with respect to the outer tube 38 . This automatically moves the mobilizer element 41 to a new optimal position. The cutting action is again performed and this procedure is repeated until the full 360° has been cut and the final resection completed. The cutting blade 23 is set in the safe position and the cutting blade cover 13 together with the cutting blade 23 in safe position are moved back into the cutting device housing 1 by simultaneously pulling both handles of the cutting blade actuator 31 and cutting blade cover actuator 34 .
[0152] The activation of the various actions are performed by distinct movements of the handles 102 and 104 . The movement of the cutting blade 23 from a safe position to a stabbing position is done by rotating the knob 100 to the stabbing position (see FIG. 11 ). The rotation of the knob 100 allows a movement of the two handles 102 , 104 with respect to outer tube 110 and prevents any other movement of the handles 102 , 104 with respect to each other. In the stabbing positions the handles 102 , 104 can be moved towards the outer tube 110 to perform the stabbing action. When the knob 100 is set in the safe position, this results in freezing the position of the handles 102 , 104 with respect to each other with the blade in the safe position. Also in the safe position the handles 102 , 104 can be moved together with respect to the outer tube 110 in order to withdraw the cover 13 or push it outwards through an existing hole in the fornix. When the knob 100 is set in the cutting position, it enables movement of the handles 102 , 104 with respect to each other moving the blade 23 from the safe position to a fully cut position and vice versa. This position of the knob 100 prevents movement of the handle 104 operating the cutting blade housing with respect to outer tube 110 .
[0153] FIG. 20 a - 20 c show an example of an embodiment of an operating assembly of the cutting device described above. The embodiment of the operating assembly of the cutting device may include a knob 100 that is slidably or rotatably connected with a part that includes the second handle 104 . The knob 100 may comprise a slot 116 that cooperates with a notch 114 on the first handle 102 or a part that is fixedly connected with the first handle 102 . The knob 100 may have three positions, i.e.:
a first end position (shown in FIGS. 20 a and 20 b ) in which the first and the second handle 102 , 104 are moveable relative to each other and in which the cutting blade 23 protrudes proximally from the cutting blade cover 13 and can make a cutting movement by moving the second handle 104 relative to the first handle 102 ; an intermediate position (shown in FIG. 20 c ) in which the first and the second handle 102 , 104 are fixed relative to each other and in which the cutting blade 23 is completely covered by the cutting blade cover 13 ; and a second end position (shown in FIGS. 20 d and 20 e ) in which the first and the second handle 102 , 104 are fixed relative to each other and in which the cutting blade 23 is protruding distally from the cutting blade cover 13 . In the second end position both the first and the second handle 102 , 104 may be move relative to the cutting device housing 1 to withdraw the cutting blade 23 with the cutting blade cover 13 into the cutting device housing 1 or to push the cutting blade 23 with the cutting blade cover 13 out of the cutting device housing 1 to protrude from that cutting device housing 1 . By that movement the cutting blade 23 may stab through the fornix of the uterus.
[0157] Although illustrative embodiments of the present invention have been described above, in part with reference to the accompanying drawings, it is to be understood that the invention is not limited to these embodiments. The cutting device may also be used in other applications, for example removel of a part of the intestine.
[0158] It should be noted that another invention is contemplated that is directed to a manipulator assembly without a cutting device. Such a manipulator assembly can be embodied as the hysterectomy assembly described in claims 11 - 29 but without the features that relate to the cutting device. Such a manipulator assembly may be the object of a divisional application. More particularly, the handle with an inner part and an outer tube that are rotatable relative to each other around a first axis A1 and a manipulator element that is connected with the handle so as to moveable along a cone without rotating around its own, second axis A2 may be beneficial relative to the known manipulators. Especially the gear assembly of the disclosed hysterectomy assembly may be used in such a manipulator assembly.
[0159] Variations to the disclosed embodiments can be understood and effected by those skilled in the art in practicing the claimed invention, from a study of the drawings, the disclosure, and the appended claims. Reference throughout this specification to “one embodiment” or “an embodiment” means that a particular feature, structure or characteristic described in connection with the embodiment is included in at least one embodiment of the present invention. Thus, the appearances of the phrases “in one embodiment” or “in an embodiment” in various places throughout this specification are not necessarily all referring to the same embodiment. Furthermore, it is noted that particular features, structures, or characteristics of one or more embodiments may be combined in any suitable manner to form new, not explicitly described embodiments. | A cutting device, for example for use in a method for laparoscopic hysterectomy wherein final resection of a uterus is executed using a vaginal approach, i.e. cutting from the vaginal side inwards, instead of cutting from the abdominal side outwards of the uterus. A hysterectomy assembly for such a method is also disclosed. | 0 |
TECHNICAL FIELD
The present invention relates to an improved thermal relief vent for a fuel tank wherein a thermal relief ring creates a mechanical seal within the vent and, more particularly, to an improved thermal relief vent wherein a thermal relief ring is crimped in place by the vent cap. The crimped thermal relief ring creates a mechanical seal between the vent and the vent cap, up until a predetermined thermal relief point, at which time the thermal relief ring will soften and/or melt and release the vent cap from the remainder of the vent.
BACKGROUND OF THE INVENTION
Fuel tanks, such as those used on commerical vehicles, are subject to a number of safety requirements. One of these safety requirements is the inclusion of a thermal relief system that allows venting of pressure within the fuel tank when the tank reaches a predetermined temperature. One type of thermal relief system is disclosed in U.S. Pat. No. 5,111,837 to Morris, which discloses a termal relief valve including a ring of fusible material that is cast in situ within a chamber positioned between an abutment member and a plate. At elevated temperatures the fusible material melts to allow the plate and the abutment member to slide relative to each other such that the plate may move outwardly from the vent, thereby releasing pressure within the fuel tank.
There are several disadvantages with such an in situ casting method. In particular, molten fusible material, such as molten metal, is required which requires subjecting workers to the hazards of handling high temperature molten metals. There are costs in generating and maintaining the molten material, as well as the safety equipment that must be purchased to work with such molten material. Additionally, employers generally must monitor the level of toxic metals in employee's bodies to ensure the safety of the process.
The in situ casting method, which involves injecting molten metal into a cavity, could result in air bubbles or an otherwise imperfect fill of the cavity, rendering the cast ineffective. Moreover, an imperfectly filled cavity may not be readily visible or otherwise detectible, such that a defective thermal relief vent may be sold to end consumers and installed on a vehicle. Additionally, the releasable vent plate generally must be held in position before, during and for a short time period after the molten material is poured, so that the molten material will solidify with the plate correctly positioned. The logistics of holding the plate in place before, during and shortly after the molten material is poured adds complexity to the in situ casting process.
SUMMARY OF THE INVENTION
The present invention provides an improved thermal relief vent for a fuel tank, and a method of manufacturing the same, wherein a thermal relief ring is used to create a mechanical seal within the vent. More particularly, the improved thermal relief vent includes a thermal relief ring that, at room temperature, is crimped in place by the vent cap itself. The crimped thermal relief ring creates a mechanical seal between the vent and the vent cap, up until a predetermined thermal relief point, at which time the thermal relief ring will soften and/or melt and release the vent cap from the remainer of the vent.
The manufacturing process of crimping a solid ring of fusible material in place with use of the vent cap itself alleviates many disadvantages of the prior art. Namely, use of a room temperature ring of fusible material eliminates many hazards and expenses associated with the use of molten metal. Additionally, use of a ring of fusible material eliminates the problems associated with casting such as air bubbles and partially filled casting chambers. Moreover, crimping of the fusible ring by use of the vent cap itself eliminates the need for holding the cap in place during casting.
In a preferred embodiment the method comprises providing a ring of fusible material, such as lead, and crimping the lead ring in place between the body of the vent and a vent cap by applying pressure to the vent cap when seated on the vent body. Crimping of the ring of fusible material causes the ring to “flow” into and around one or more annular grooves positioned on an inside surface of the vent body and on an exterior surface of the vent cap, to create a mechanical seal between the body and the cap.
Accordingly, an object of the present invention is to provide a thermal relief vent that provides an airtight seal on a fuel tank during normal thermal conditions.
Another object of the present invention is to provide a thermal relief vent that releases pressure within a fuel tank upon the tank reaching a predetermined temperature.
Still another object of the present invention is to provide a thermal relief vent that is installed without the use of molten fusible material.
Yet another object of the present invention is to provide a thermal relief vent that is manufactured by a mechanical crimping operation.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a cross-sectional view of the thermal relief vent with the vent cap and ring of fusible material crimped therein, with the vent shown in a pressurized configuration;
FIG. 2 is a cross-sectional view of one embodiment of the vent cap;
FIG. 3 is an isometric view of the ring of fusible material;
FIG. 4 is a cross-sectional view of the thermal relief vent with the vent cap and ring of fusible material crimped therein, with the vent shown in a non-pressurized configuration;
FIG. 5 is a detailed cross-sectional view of one embodiment of the cap and ring of fusible material prior to crimping thereof;
FIG. 6 is a detailed cross-sectional view of the cap and ring of fusible material after crimping thereof; and
FIG. 7 is an isometric view of the float and the float seal of the thermal relief vent.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring to the figures, FIG. 1 shows a cross-sectional view of the thermal relief vent 10 with the vent cap 12 positioned on the vent body 14 , and a ring of fusible material 16 crimped therein, with the vent shown in a pressurized configuration. In the embodiment shown, vent body 14 comprises an elongate float section 18 , also referred to as a cage tube section 18 , which houses a ball 20 and a float 22 . Cage body 18 includes a crimped end portion 24 which prevents the exit of ball 20 and float 22 from an interior 26 of cage body 18 . The crimped end portion 24 and apertures 28 allow fuel and pressure within the fuel tank to communicate with interior 26 of cage body 18 . In a pressurized configuration, i.e, when the interior of the fuel tank and therefore the interior 26 of the cage body 18 is subject to a pressure above a first predetermined value, or in the condition of partial tank rollover, the fuel level will cause float 22 to move in a direction 30 within vent body 14 such that a seal 32 positioned on float 22 will contact a vent valve 34 , having a lower opening 34 a , positioned within a neck portion 36 of vent body 14 . A spring 38 is positioned within neck portion 36 of the vent body 14 , and, up until a second predetermined pressure is exerted against the spring in direction 30 , the spring 38 exerts a pressure on vent valve 34 in a direction 40 , forcing an O-ring 42 of the vent valve 34 against a seat 44 , or shoulder 44 , of neck portion 36 of vent body 14 . Once the pressure within the tank exceeds the second predetermined pressure, float 22 moves further in direction 30 , thereby forcing vent valve 34 further in direction 30 , thereby slightly compressing spring 38 in direction 30 . This movement of vent valve 34 in direction 30 , so that O-ring 42 is no longer in contact with shoulder 44 , allows fuel or pressurized gas within the fuel tank and vent to escape from the vent 14 through an aperture 46 of neck portion 36 and out of the vent body 14 through a hose barb 48 .
Still referring to FIG. 1 , spring 38 is retained within neck portion 36 of the vent body 14 by vent cap 12 and ring of fusible material 16 . In particular, during assembly of thermal relief vent 10 , ring of fusible material 16 (shown more clearly in FIG. 3 ) is positioned in an annular recess 50 of vent neck portion 36 . Vent cap 12 is then crimped on the vent body 14 , i.e., vent cap 12 is forced in direction 40 against ring of fuisible material 16 . Ring 16 typically is manufactured of a thermal relief material, i.e, a material that will soften or otherwise yield upon reaching a predetermined temperature. In a preferred embodiment, ring 16 is manufactured of an alloy of lead, but other thermal relief materials may be utilized for particular applications. As vent cap 12 is forced or crimped in direction 30 , fusible ring 16 “flows around” one or more threads 52 on vent cap 12 , one or more threads 54 in annular recess 50 of vent neck portion 36 , and throughout annular recess 50 of neck portion 36 and throughout recess 51 of vent cap 12 . Vent cap 12 is crimped on vent body 14 until a shoulder 56 of the vent cap 12 abutts the top portion 58 of vent body 14 . With the cap 12 in this crimped position on body 14 , the ring of fusible material 16 has “flowed” around threads 52 and 54 , and typically has filled annular recesses 50 and 51 such that ring 16 creates a mechanical and an airtight seal between vent cap 12 and vent body 14 . Accordingly, in the method of manufacturing the thermal relief vent 10 of the present invention, vent cap 12 itself is used as the force mechanism to seat ring 16 .
Use of cap 12 itself to apply a force to ring 16 eliminates the positioning problems posed by the prior art wherein the cap must be held in place while molten metal is injected around the cap. Moreover, the crimping method of the present invention eliminates the need for the use of molten metal, thereby eliminating the hazards and costs associated with molten metal casting operations. Additionally, the ring 16 of fusible material utilized in the present invention typically has a circumference that matches the circumference of annualar recess 50 of neck portion 36 such that the mechanical seal of fusible material positioned between vent cap 12 and vent body 14 fills the entirety of annualar recesses 50 and 51 and does not include air pockets, as do some cast seals of the prior art.
As stated above, ring 16 typically is manufactured of a thermal relief material, i.e, a material such as a lead alloy that will soften or otherwise yield upon reaching a predetermined temperature. For example, when thermal relief vent 10 , or the contents within a fuel tank on which the vent is mounted, reaches a predetermined temperature, the fusible material will also be subjected to the predetermined temperature. Upon reaching this predetermined temperature, fusible material 16 will soften or yield, thereby allowing cap 12 to become loosened with respect to vent body 14 . Upon softening of fusible material 16 , the mechanical seal created by the fusible material is weakened such that spring 38 , or pressure within interior 26 of vent body 14 , will force vent cap 12 from vent body 14 in direction 30 . Once vent cap 12 is forced from vent body 14 , pressure within interior 26 of the vent body is vented out an opening 60 of vent body 14 .
Each of the components of vent 10 typically are manufactured of a material that will withstand the high temperatures and pressures, and the harsh environmental conditions associated with the commercial trucking industry. In one embodiment, cap 12 , body 14 and hose barb 48 are manufactured of brass. Float ball 20 and spring 38 may be manufactured steel. Float 22 typically is manufactured of plastic or another like bouyant material. Seal 32 and O-ring 42 typically are manufactured of a flexible material, such as rubber, plastic or the like.
FIG. 2 shows a cross-sectional view of vent cap 12 including shoulder 56 , external threads 52 , annular recess or groove 51 , and an interior recess 62 for receiving spring 38 . Annular groove 51 defines a diameter 64 and shoulder 56 defines a slightly larger diameter 66 .
FIG. 3 shows an isometric view of the ring of fusible material 16 . Ring 16 typically has a diameter 68 approximately the same size as diameter 64 of cap 12 , and smaller than diameter 66 of cap 12 . Ring 16 may be manufactured by taking an elongate piece of fusible material, cutting it to a preferred length, and then bending it into a circular shape as shown in FIG. 3 such that ends 70 and 72 abutt one another. In another embodiment, ring 16 may be manufactured by taking an elongate piece of fusbile material, cutting it in a preferred length, and then bending it into a circular shape such that ends 70 and 72 overlap one another. In yet another embodiment, ring 16 may be stamped, such as in the circular shape as shown, from a sheet of fusible material. In still another embodiment, ring 16 may be cast from molten material. Applicants note that such a casting method may be conducted for the fabrication of ring 16 , prior to placement of the solid, previously formed ring 16 within body 14 . In a preferred embodiment, a lead “wire” is wound into a helix on a mandrel. The helix is then cut along the length of the mandrel to form many lead rings with a single cut.
FIG. 4 shows a cross-sectional view of the thermal relief vent 10 in a nonpressurized configuration. In particular, float 22 is shown in a lowered position such that seal 32 on the float is not in contact with vent valve 34 .
FIG. 5 shows a detailed cross-sectional view of the cap 12 , body 14 and ring 16 of fusible material prior to crimping thereof. Prior to crimping of cap 12 to vent body 14 , cap 12 is positioned above opening 60 of the vent body. Cap 12 may be held in such a position, for example, manually by a assembly device 73 that has a recess 75 into which the top portion 74 of cap 12 seats. Recess 75 generally is similar in shape to cap 12 such that device 73 is self aligning. Cap 12 is held in this seated and centered posiiont by the force of spring 38 (not shown in this figure). Ring 16 is positioned on shoulder 44 , within annular recess 50 and adjacent threads 54 of of vent body 14 . A diameter 76 of threads 54 and recess 50 of vent body 14 typically is slightly larger than diameter 64 of threads 52 and recess 51 of cap 12 such that the threads 52 and 54 do not mate with one another but are positioned adjacent one another. In this manner, fusible material 16 may “flow” around threads 52 and 54 , and through recesses 50 and 51 so as to secure cap 12 on vent body 14 . In another embodiment, threads 52 and 54 may mate with another another (such that diameters 64 and 76 are approximately the same size), thereby requiring cap 12 to be twisted or turned with respect to body 14 , in order for cap 12 to be received within annular recess 50 of vent body 14 . In this embodiment wherein the threads mate with one another, a sufficient amount of space will still remain between the mating threads so that ring 16 will “flow” around threads 52 and 54 during crimping of cap 12 to body 14 .
FIG. 6 shows a detailed cross-sectional view of cap 12 , body 14 and ring 16 of fusible material after crimping thereof wherein assembly fixture 73 has been removed. In particular, to secure cap 12 to body 14 , cap 12 is moved in direction 40 toward body 14 by assembly 73 with a force great enough to cause fusible material 16 to flow, i.e., to deform, such that fusible material 16 conforms to the shape of annular recesses 50 and 51 , and threads 52 and 54 . Of course, body 14 can be moved toward cap 12 or both the body and cap may be moved toward each other. The force exerted against cap 12 and body 14 should preferrably be sufficient to cause deformation of ring 16 but less than the force required to deform cap 12 and body 14 . The amount of force required for any particular application will depend on, for example, the size and shape of threads 52 and 54 , the size of annular recesses 50 and 51 , the type of fusible material used to manufacture ring 16 , the size of ring 16 , and the depth of threads 52 and 54 . As shown in FIG. 6 , ring 16 forms a mechanical and an airtight seal between cap 12 and body 14 such that cap 12 will not become displaced with respect to body 14 until ring 16 is softened thereby allowing cap 12 to be removed therefrom.
FIG. 7 shows an isometric view of the float 22 and the float seal 32 of the thermal relief vent 10 . In the embodiment shown, float 22 comprises an elongate float having a generally square cross sectional shape wherein top surface 78 is solid and a lower surface 80 allows access to a hollow interior 82 of the float. A tab 84 extends outwardly from a side surface 86 of the float and engages an aperture 88 of seal 32 . Seal 32 , in the embodiment shown, is manufactured with a bend 90 in a midsection thereof, such that an end region 92 of the seal is positioned overlying top surface 78 of float 22 . Due to bend 90 of the seal, and due to the flexible and resilient nature of the material from which seal 32 is manufactured, end region 92 of the seal is flexibly positioned on top surface 78 of the float. As shown more clearly in FIG. 1 , top surface 78 of float 22 may include an upwardly extending projection 94 sized to be received within opening 34 a of vent valve 34 . Accordingly, in the pressurized condition shown in FIG. 1 , projection 94 is aligned with opening 34 a such that seal 32 contacts the lip of opening 34 a around a circumference thereof. Moreover, due to bend 90 of the seal 32 on float 22 , the seal is loosely positioned above top surface 78 of the float such that the seal will be correctly positioned for contact with opening 34 a of the vent valve. Because seal 32 is secured to side surface 86 , tab 84 is positioned away from top sealing surface 78 of the float and, therefore, will not interfere with sealing of the vent.
In the above description numerous details have been set forth in order to provide a more through understanding of the present invention. It will be obvious, however, to one skilled in the art that the present invention may be practiced using other equivalent designs. | An improved thermal relief vent for a fuel tank, and a method of manufacturing the same, includes a thermal relief ring that is used to create a mechanical seal within the vent. The thermal relief ring, at room temperature, is crimped in place by use of the vent cap itself. The crimped thermal relief ring creates a mechanical seal between the vent and the vent cap, up until a predetermined thermal relief point, at which time the thermal relief ring will soften and/or yield and release the vent cap from the vent body. | 5 |
BACKGROUND
[0001] The present invention relates to elongated structures such as pilings of the type used in marine applications for protecting piers, docks and similar structures from being damaged by passing and docking ships, and methods for making such pilings.
[0002] Concrete, steel, and wood are conventionally used for pilings, telephone poles, and the like. However, each of these materials has disadvantages. Concrete and steel pilings are heavy and awkward to maneuver. Neither concrete nor steel pilings make good fender pilings because neither is “forgiving” when impacted. Under impact steel bends and buckles and concrete shatters. Both concrete and steel pilings are expensive to repair. Furthermore, steel, either standing alone or as a reinforcement in porous concrete, is subject to corrosion.
[0003] Wood pilings are plagued by wear and tear and are attacked by wood-boring marine organisms. Wood pilings are typically treated with creosote, but even this material can be ineffective against modern marine borers. These marine borers can only be stopped by wrapping the wood pilings in plastic coverings. However, these plastic coverings cannot withstand much wear and tear, especially abrasion from normal vessel contact. So in addition to a thin plastic wrap, wooden fender piles often require thick plastic wrappings, which are expensive to put in place. Wood used for telephone poles is subject attack from environmental hazards such as woodpeckers, and in desert locations, there can be severe erosion from sandstorms.
[0004] Composite pilings are also known, being disclosed for example in U.S. Pat. No. 5,180,531 to Borzakian, that document being incorporated herein by this reference. The '531 patent discloses a plastic pipe having an inner pipe core or mandrel being 6 inches or less in diameter, and a substantially homogenous coating being at least two inches thick. The thick plastic coating provides the bulk of the mechanical strength, being formulated with a desired combination of flexibility, brittleness, and impact resistance for use as pilings including fender pilings of docks, telephone poles, light standards, etc. The plastic pipe of the prior art is not entirely satisfactory in that uniform thick coatings that are free of voids are somewhat difficult to achieve, and longer lengths of the pilings such as from 20 feet to 60 feet normally require assembly of shorter length segments, with consequent degradation of structural and environmental integrity and increased cost of fabrication. Also, when the plastic pipe is provided with the homogenous plastic coating having with a desired flexibility and impact resistance for fender piling applications, the bending strength is less than desired for withstanding side loads that are produced by contact with approaching vessels. Pilings of similar construction incorporating larger pipe mandrels are also known.
[0005] U.S. Pat. No. 5,766,711 to Barmakian discloses a composite camel structure including a pipe mandrel and a thermally bonded plastic cushion surrounding the mandrel, that patent being incorporated herein by this reference. A mold having the mandrel centered therein is filled with molten plastic, the plastic being cooled and solidified by feeding water into the mandrel for progressively solidifying the cushion member along mandrel for producing a thermal bond without excessive tensile strain in the plastic material, thereby to achieve a substantially unbroken outside surface.
[0006] Another known form of composite piling, which is described in U.S. Pat. No. 6,244,014 to Barmakian and incorporated herein by this reference, incorporates a welded cage structure including longitudinal bars that are connected by a spiral member, the cage structure being encapsulated in a resilient plastic.
[0007] A further form of composite pilings incorporates a thin-wall cylindrical tubular member formed of carbon filament-reinforced plastic that is filled with concrete. Unfortunately, it is prohibitively expensive to orient the carbon filament diagonally. Commercially available tubular members of this type have a substantially purely circumferential filament orientation and consequently this type has little bending and shear strength, even in combination with the concrete core. Further, these pilings are quite brittle, having little ability to withstand side impacts by ships and other vessels in marine applications.
[0008] In view of these problems with existing thin-wall pilings, there is a need for elongated structures for marine use that are inexpensive to provide, yet have a long life, are easily installed, environmentally sound, durable in use, having high bending and shear strength. There is a further need for such structures having great energy absorbing capacity when subjected to side impact loads.
SUMMARY
[0009] The present invention meets these needs by providing a composite structure that is low in cost and has particularly high bending and shear strength. In some preferred configurations the structure also has a very great ability to withstand high energy side impact loading. In one aspect of the invention, the reinforced composite structure includes an elongate tubular member having first and second ends, a second end portion near the second end, a length of at least 10 feet, an outside surface defining an outer cross-sectional area of at least 28 square inches at a first location along the tubular member, and an inside surface defining a wall thickness of not more than 10 percent of an equivalent diameter of the outer cross-sectional area at the first location; and a resilient plastic body encapsulating only a portion of the outside surface of the tubular member including a portion near the first end, the plastic body extending on the outside surface of the tubular member not closer to the second end than 20 percent of the length of the tubular member for facilitating secure and rigid planting of the composite structure in soil. Preferably the encapsulation extends lengthwise on the outside surface of the tubular member for at least three equivalent diameters of the outer cross-sectional area outside and inside surfaces for enhanced structural integrity of the plastic body. The encapsulated portion of the tubular member can extend to the first end of the tubular member, it can be approximately flush with the first end of the tubular member, or it can encapsulate the upper end of the tubular member. Also, the plastic body can substantially fill the tubular member.
[0010] The tubular member can include a fiber-reinforcing material, such as fiberglass.
[0011] Preferably the composite structure includes a reinforcing element contacting the inside surface of the tubular member. The reinforcing element can include a shear-resistant material substantially filling the tubular member. The shear-resistant material can be concrete. Also, or in the alternative, the reinforcing element can include an elongate reinforcing member extending within the tubular member and being in proximate contact with a portion only of its inside surface. The reinforcing member can include a longitudinally distributed plurality of loop elements. Adjacent loop elements of the reinforcing member can have a pitch spacing between approximately 25 percent and approximately 70 percent of the equivalent outside diameter of the tubular member, and the loop elements can be helically formed. The reinforcing member can include a material selected from steel, nickel, carbon fiber, and fiberglass. The reinforcing member can have a cross-sectional area of between 0.02 percent and approximately 0.2 percent of the overall cross-sectional area of the tubular member.
[0012] Preferably at least a portion of the plastic body has a radial thickness outside of the tubular member that is not less than approximately 5 percent of a co-located circumference of the tubular member, the term co-located meaning located along the tubular member within the portion of the plastic body.
[0013] Preferably the plastic body consists of a main polymeric component and an additive component, the main polymeric component consisting of low-density polyethylene of which at least 60 percent is linear low density stretch film polyethylene, the additive component including an effective amount of an ultraviolet inhibitor. More preferably, the main polymeric component is at least 90 percent of the plastic body, the plastic body including not more than 5 percent by weight of high-density polyethylene.
[0014] In another aspect of the invention, a method for forming a composite structure includes the steps of providing an elongate tubular member; and encapsulating an end portion of the tubular member in a plastic body, the tubular member having an overall length of not less than approximately 10 feet, an overall cross-sectional area of at least 28 square inches at an axial extremity of the plastic body closest to the second end of the tubular member, and a wall thickness being not more than 10 percent of a diameter equivalent to said overall cross-sectional area.
[0015] The method can include the further step of inserting a reinforcing element into the tubular member, the reinforcing element contacting the inside surface for stiffening the tubular member. The reinforcing element can include a reinforcing member, the method including the further steps of forming the reinforcing member as a rod member having a longitudinally spaced plurality of loop elements and, prior to the encapsulating, inserting the rod member into the tubular member with at least a portion of each of the loop elements contacting circumferentially spaced locations on the inside surface of the tubular member.
[0016] Alternatively, or additionally, the step of inserting can include feeding a liquidic reinforcing material into the tubular member, and solidifying the liquidic material. The liquidic material can include material of the plastic body and/or concrete.
[0017] The encapsulating can include the steps of providing an injection mold having an elongate cylindrical cavity; loading the mold with the tubular member such that a portion of the tubular member projects from a main cavity portion of the mold; injecting a polymeric composition into the mold thereby encapsulating a portion of the tubular member; and cooling the mold to form the composite structure. Preferably the step of injecting includes formulating the polymeric composition to consist of low density polyethylene, at least 60 percent of the polymeric composition being linear low-density stretch film polyethylene for resisting cracking of the material.
[0018] In a further aspect of the present invention, a method for forming a cushioned fender in a marine environment having underwater soil, includes the steps of selecting a reinforced composite structure as first given above; and driving the second end of the tubular member into the soil to a depth effective for stabilizing the tubular member and for positioning the plastic body as a cushioned barrier above the soil.
DRAWINGS
[0019] These and other features, aspects, and advantages of the present invention will become better understood with reference to the following description, appended claims, and accompanying drawings, where:
[0020] FIG. 1 is a sectional elevational view of a reinforced composite piling according to the present invention, the piling being installed in a marine environment for fending off passing vessels;
[0021] FIG. 2 is a bottom view of the piling of FIG. 1 ;
[0022] FIG. 3 is a sectional elevational view as in FIG. 1 , showing an alternative configuration of the composite piling;
[0023] FIG. 4 is a lateral sectional view of a mold assembly in use making the composite piling of FIG. 1 , illustrating the flow of extruded plastic within and around a spiral reinforcing member thereof; and
[0024] FIG. 5 is a flow chart for a process of forming the piling structure of FIG. 1 .
DESCRIPTION
[0025] The present invention provides a novel reinforced composite structure that is particularly effective as a fender in association with a ship mooring or other harbor structure. With reference to FIGS. 1 and 2 of the drawings, a composite structure or piling 10 according to the present invention includes an elongate tubular member 12 and a resilient plastic material forming a plastic body 14 encapsulating an upper portion of the tubular member. As shown in FIG. 1 , the piling 10 can be implanted in soil 16 under a body of water 18 such that the plastic body 14 is positioned for blocking the hull of a ship 20 in a cushioned manner, the plastic body being confined to that portion of the tubular member 12 that is not in the soil 16 .
[0026] An exemplary configuration of the piling 10 has the tubular member 12 and an outer perimeter of the plastic body 14 formed generally circularly cylindrical with a diameter B at a distance W outwardly from the tubular member 12 as shown in FIG. 2 , the tubular member having an outside diameter D (See FIG. 1 .) that is typically between 8 and 36 inches, and a length L that is typically between approximately 10 feet and approximately 60 feet. Even longer lengths such as 100 feet are also contemplated, although coupling to extension pilings in locations of deep mud deposits is generally preferred. A preferred embodiment of the tubular member 12 is formed of glass fiber-reinforced epoxy (referred to herein as “fiberglass”), having a wall thickness T that can be from approximately 0.125 inch up to approximately 2 inches. As used herein, the term “cylindrical” means having a surface that is generated by a straight line that moves parallel to a fixed line. Thus, although the tubular member 12 and the perimeter surface of the body 14 are shown in the drawings as being circularly cylindrical, other cross-sectional shapes such as elliptical, polygonal, and rounded polygonal are also contemplated within the scope of the present invention. In these alternatives, the tubular member 14 typically has an overall cross-sectional area of at least approximately 50 square inches, although smaller sections such as having approximately 28 square inches are contemplated, being equivalent to approximately 6 inches diameter. Further, this invention is not limited to cylindrically shaped cores, as axially tapered and other tubular shapes are contemplated. Moreover, other materials are contemplated for the tubular member, including carbon filament-reinforced plastic and steel.
[0027] Also, although the plastic body 14 is shown radially projecting a uniform distance W outwardly from the tubular member 12 to a body diameter B for a distance or encapsulated length l downwardly from the upper extremity of the tubular member, the body 14 need not be concentric with the tubular member 12 . Further, the perimeter surface of the body 14 is not required to be circular or even cylindrical; a variety of other shapes such as frusto-conical and ellipsoidal are contemplated within the scope of the present invention, although at least a portion of the plastic body preferably has a radial thickness outside of the tubular member being not less than approximately 5 percent of a co-located circumference of the tubular member. Moreover, the plastic body 14 projects outwardly from the tubular member over a body length C, which can extend a distance E beyond the upper end of the tubular member 12 , the piling 10 having an overall length F. As further shown in FIG. 1 , the composite piling 10 extends to a height H above the soil 16 when driven a sink distance S into the soil. The sink distance S will normally be at least 20 percent of the length L of the tubular member 12 . Accordingly, the encapsulated length l is normally less than 80 percent of the length L, preferably less than 75 percent of the length L for avoiding contact with or partial penetration with the soil, with consequent potential for partial separation of the plastic body from the tubular member and/or reduced stiffness of the implantation of the piling 10 . Also, the encapsulated length l is normally not less than approximately 3 times the diameter D of the tubular member. More generally for tubular members of non-circular cross-section, the encapsulated length l is not less than 3 equivalent diameters of the tubular member, the term equivalent diameter being the diameter of a circular cross-section having the same area as that of the non-circular cross-section. More preferably, the encapsulated length l is between approximately 30 percent and approximately 50 percent of the length L for providing effective cushioning over an expected range of contact locations while avoiding the use of ineffective quantities of material of the plastic body 14 .
[0028] An optional feature of the composite piling 10 is a reinforcing element that extends proximate an inside surface 24 of the tubular member for resisting inward deformation of the tubular member under high transverse loading such as when the piling 10 is subjected to impact contact by the ship 20 , or in the event that the ship 20 being restrained by the piling is subjected to high winds. In the exemplary configuration of FIGS. 1 and 2 , the reinforcing element is a reinforcing member 22 in the form of rod of generally uniform cross-section having helically formed loop elements 23 that contact the inside surface 24 of the tubular member 24 along substantially the full length thereof.
[0029] In the exemplary configuration of FIGS. 1 and 2 , the plastic body 14 substantially fills the space inside the tubular member 12 that is not occupied by the reinforcing member 22 . In applications wherein bending loading is not severe, the reinforcing member 22 can be omitted and the plastic body 14 filling at least a portion of the tubular member functions as the reinforcing element. In applications having severe bending loads, a reinforcing structure (incorporating the reinforcing member 22 or in addition thereto) can be imbedded in the tubular member. (The glass fibers of the exemplary fiberglass tubular member 12 , described above, serve as such a reinforcing structure.) The reinforcing member 22 can be a conventional formed steel reinforcing rod of the type commonly used for reinforcing concrete (available, for example from J.L. Davidson Co. of Rialto, Calif.). Other suitable forms of the reinforcing member 22 include nickel reinforcing rod (available from MMFX Steel Corp. of America, Charlotte, N.C.), fiberglass reinforcing rod (available from Hughes Brothers fiberglass of Seaward, Nebr., and carbon fiber reinforcing rod (available from Aero Space Composite Products of San Leandro, Calif.).
[0030] In a preferred configuration wherein the outside diameter D of the tubular member 12 is on the order of 8 or 10 inches, the thickness T being between approximately 0.12 inches and approximately 0.25 inches, a suitable diameter of the reinforcing member 22 is nominally ⅜ inch in diameter. A suitable spacing or pitch P of the loop elements 19 is approximately 5 inches, or about half of the outside diameter D. More generally, the diameter of the reinforcing member 22 can be from approximately 0.25 inch to approximately 0.75 inch.
[0031] In a variety of applications, it is contemplated that the outside diameter D of the tubular member 12 can be from approximately 8 inches to approximately 36 inches. The radial thickness W of the plastic body 14 can range from approximately 0.25 inch to approximately 24 inches. Practical combinations of these dimensions include the wall thickness T of the tubular member being from approximately 1.5% to approximately 10% of D, the radial thickness W of the plastic body 14 being from approximately 3% to approximately 100% of the diameter D of the tubular member 12 .
[0032] With further reference to FIG. 3 , an alternative configuration of the composite piling, designated 10 ′, incorporates a shear member 30 that preferably fills the space within the tubular member 12 that is not occupied by the reinforcing member 22 . A suitable and preferred material for the shear member 30 is concrete. It will be
[0033] An important feature of the present invention is a formulation of polymeric material that is suitable for encapsulating the tubular member 12 and that does not form voids and cracks due to tensile thermal strains being generated during solidification. This problem is exacerbated by the absence of a tubular mandrel that can receive cooling water as disclosed in the camel structure of the above-referenced '711 patent. As described in the above referenced U.S. Pat. No. 6,244,014 which is incorporated herein, it has been discovered that a particularly suitable composition for forming the plastic body 14 as an uninterrupted covering that also fills the tubular member 12 is a main first quantity of low density polyethylene of which at least 60 percent and preferably 65 percent is linear low-density polyethylene (LLDPE), the balance being regular low-density polyethylene (LDPE), and a process additive second quantity which may include a foaming or blowing agent, a coupling agent, a fungicide, an emulsifier, and a UV inhibitor such as carbon black, the composition not having any significant volume of filler material such as calcium carbonate. Preferably, the first quantity is at least 90 percent of the total volume of the plastic body 14 , approximately 5 percent of the total volume being a mixture of coloring, foaming agent, and UV inhibitor. Preferably the composition is substantially free (not more than 5 percent) of high density polyethylene.
[0034] Thus the composition of the cushion member 14 has polymeric elements being preferably exclusively polyethylene as described above (substantially all being of low-density and mainly linear low-density), together with process additives. As used herein, the term “process additive” means a substance for enhancing the properties of the polymeric elements, and does not include filler material such as calcium carbonate.
[0035] With further reference to FIG. 4 , a mold apparatus 40 for encapsulating the cage 12 to form the plastic body 14 of the piling 10 includes a mold assembly 42 , a mold cradle 44 , and a conventional extruder press having an outlet 46 . The mold assembly 42 includes a flanged tubular mold segment 48 , an inlet plate 50 having an injection point 52 for connection to an outlet of the extruder press, and a back plate 54 through which the tubular member 12 projects, the back plate 54 having an exhaust vent 55 .
[0036] As further shown in FIG. 4 , the mold segment 48 has an inside diameter D′ and a length L′, being a weldment of a mold tube 78 and a pair of perforate flanges 80 . The diameter D′ and the length L′ of the mold segment 48 correspond to the body diameter B and length C, but with allowance for shrinkage of the material of the plastic body 14 . For example, with the inside diameter D′ being 13.25 inches, the body diameter B subsequent to cooling of the plastic body 14 is approximately 13.0 inches. Respective pluralities of flange fasteners 84 provide removable connections between the flanges 80 and the corresponding inlet and back plates 50 and 54 . Suitable materials for the mold tube 78 and the flanges 80 include mild steel of 0.25 inch and 1 inch thickness, respectively. It will be understood that additional counterparts of the mold segment 48 can be connected end-to-end with the segment 48 for selectively varying the length C of the body member 14 .
[0037] Also shown in FIG. 5 is the tubular member 12 centered within a main cavity 60 of the mold assembly 42 , being supported relative to the back plate 54 and a rear element 62 of the mold cradle 44 that also supports the mold assembly 42 . The back plate 54 is provided with a plurality of flanged inserts 56 that are fastened thereto by fasteners 58 for facilitating insertion of the tubular member 12 as well as for providing an effective seal between the back plate 54 and the tubular member. The rear element 62 has a cavity 64 formed therein for locating the projecting extremity of the tubular member 12 , the cavity 64 closely fitting the outside of the tubular member to provide a seal for the material of the body member 14 being molded therein, and having a counterpart of the exhaust vent, designated 55 ′. The mold cradle 44 also includes a medial element 66 and a front element 68 on which rests the mold tube 78 , the medial element also engaging the perforate flange 80 to which the back plate 54 is fastened for limiting the projection of the tubular member from the mold assembly 42 . Further, the rear element 62 is stepped as indicated at 70 for facilitating location of the tubular member 12 first by lowering the member and then by axially displacing the member outwardly from the mold assembly 42 . Alternatively, the rear element 62 can be assembled from a cradle portion and a cavity portion, the cavity portion being attached subsequent to positioning of the mold assembly 42 and the tubular member, and this form of the rear element 62 can be made a part of the mold assembly 42 . Additionally or alternatively to the centering by the rear element 62 , the tubular member can be centered within the mold assembly 42 by means described in the above-referenced U.S. Pat. No. 6,244,014, provided that a suitable means for keeping the tubular member axially located is included.
[0038] The mold assembly 42 and the mold cradle 44 can also be used in formation of the composite piling 10 ′ of FIG. 3 , the shear member 30 having been formed by conventional means prior to molding the plastic body 14 . In this embodiment, there is no need for sealing engagement at the projecting extremity of the tubular member 12 or for the exhaust vent 55 ′.
[0039] With further reference to FIG. 5 , a molding process 100 for forming the composite structure or piling 10 includes inserting the reinforcing member 22 into the tubular member 12 in a load reinforcing step 102 , a form shear member step 103 (when the process 100 is for forming the piling 10 ′), a load mold step 104 wherein the tubular member 12 is placed within the mold assembly 42 with one end thereof projecting from the back plate 54 , a cradle step 106 wherein the tubular member 12 is coaxially centered within the mold tube 78 by being supported, for example, by the rear element 62 of the mold cradle in combination with the back plate 54 , the tubular member also projecting a predetermined distance from the back plate 54 corresponding to the extension distance E being that desired. The mold assembly 42 is closed, for example, by installing the inlet and/or back plates 50 and 54 , in a close mold step 108 and, optionally in an incline mold step 110 , the mold assembly 42 is propped up on a suitable support for elevating the exhaust vents 55 and 55 ′. It will be understood that the back plate can be attached to the medial element 66 prior to connecting the mold tube 78 . Also, the mold cradle 44 can be constructed so as to support the mold assembly 42 in an inclined condition initially. Further, it may be desirable to bond or otherwise fixably locate the reinforcing member to the inside surface 24 of the tubular member 12 for increased bending strength of the composite piling 10 .
[0040] Next, the material of the plastic body 14 is fed into the main cavity 60 in an inject body step 112 . Then in a cooling step 114 , the mold assembly 42 with its contents is submerged in cooling water for solidifying the material of the plastic body 14 , after which the assembly 42 is removed from the water (step 116 ), opened and the completed piling 10 is withdrawn in a remove structure step 118 .
[0041] If desired or needed, the tubular member 12 and/or the mold assembly 42 can be preheated to be certain that the plastic material of the cushion member 14 flows to the cover plate 54 of the mold assembly 42 and completely fills the main cavity 60 as well as the tubular member 12 .
[0042] The piling 10 of the present invention is immune to marine borer attack, and thus requires no further protection, such as creosote or plastic sheathing, being practically maintenance free. The piling 10 is abrasion resistant, and thus has excellent effectiveness as a marine fender piling without any added protective covering.
[0043] The composite piling 10 is chemically inert, so it can last indefinitely. It does not react with sea water, is corrosion free, is substantially immune to the effects of light, is not bothered by most petroleum products, and is not subject to dry rot. Because it can be made with recycled plastic, it is an environmentally sound investment.
[0044] In some military based naval applications, it is undesirable for a piling to be electro-magnetically sensitive. In such applications the reinforcing member 22 can be formed with non-magnetic materials, such as carbon-reinforced plastic.
[0045] Although the present invention has been described in considerable detail with reference to certain preferred versions thereof, other versions are possible. For example, the tubular member 12 can be flush with one end of the plastic body 14 , or the tubular member project from both ends of the plastic body. In the first case, the inlet plate 50 would be formed for feeding the material for the plastic body 14 of the piling 10 of FIGS. 1 and 2 both outside and inside of the tubular member 12 . In the second case, separate paths for the material for the plastic body 14 would be provided, either in a single operation or separate molding operations. Similarly for the piling 10 ′ of FIG. 3 , the inlet plate 50 would be formed for feeding material outside of the tubular member only, such as by incorporating a pair of injection points 52 on opposite sides of counterparts of the flanged inserts 56 . Therefore, the spirit and scope of the appended claims should not necessarily be limited to the description of the preferred versions contained herein. | A composite structure that can serve as a cushion or fender piling for moored or passing ships includes an elongate tubular member having a radially projecting resilient cushion extending over an upper portion of its length. In one embodiment, the material of the cushion also fills the tubular member, encapsulating an upper extremity of the tubular member. In another embodiment, the tubular member is filled with a different material such as concrete, and the material of the cushion can also encapsulate upper extremities of both the tubular member and the different filler material. Optionally, a reinforcing member such as a helically formed length of reinforcing bar engages an inside surface of the tubular member for resisting inward deflection of the tubular member when the piling is subjected to high bending and shear loading. | 4 |
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